ASSEMBLY GUIDE

PART NO. 4186403 8000 SRM 2056

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Hyster®
dealer. Service Manuals provide general guidelines for maintenance and service and are intended for
use by trained and experienced technicians. Failure to properly maintain equipment or to follow
instructions contained in the Service Manual could result in damage to the products, personal injury,
property damage or death.
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to
support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift
trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or
exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to
remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit
needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels and when
working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the
area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:

WARNING
Indicates a hazardous situation which, if not avoided, could result in death
or serious injury.

CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
 Table of Contents

TABLE OF CONTENTS
Series Code / Model Designation Reference Table ................................................................................................ 1
General .....................................................................................................................................................................1
Weights and Dimensions ........................................................................................................................................ 2
Loading Procedures .................................................................................................................................................5
Loading Truck on a Transport ............................................................................................................................5
Loading Disassembled Components ...................................................................................................................5
Unloading Procedures ............................................................................................................................................. 7
Unloading Truck From Transport ...................................................................................................................... 7
Lifting the Truck ............................................................................................................................................. 7
Driving On/Off a Trailer ..................................................................................................................................8
Unloading Disassembled Components ............................................................................................................... 8
Moving and Towing ................................................................................................................................................. 8
Precautions .......................................................................................................................................................... 8
Moving a Disabled Truck .................................................................................................................................... 9
Truck Assembly ..................................................................................................................................................... 10
Install Lights on Boom ......................................................................................................................................10
Install Counterweight ....................................................................................................................................... 11
Install Boom and Derricking Cylinders ........................................................................................................... 11
Install Container Attachment and Damping Cylinder ................................................................................... 15
Lubrication .........................................................................................................................................................18
Automatic Greasing System (Optional) ....................................................................................................... 18
General Checks After Assembly ........................................................................................................................... 19
Plumbing Check ................................................................................................................................................ 19
Lubrication Check ............................................................................................................................................. 19
Fluid Level Check ..............................................................................................................................................19
Functionality Check .......................................................................................................................................... 19
Literature Package Check ................................................................................................................................ 19
Cleaning ............................................................................................................................................................. 19
Labels ................................................................................................................................................................. 19
Pneumatic Tires and Wheels ................................................................................................................................ 20
Remove Wheels From Lift Truck ......................................................................................................................20
Remove Tire From Wheel ................................................................................................................................. 21
Tire Removal ..................................................................................................................................................22
Install Tire on Wheel .........................................................................................................................................23
Tire Installation .............................................................................................................................................23
Adding Air Pressure to the Tires ......................................................................................................................26
Install Wheels on Lift Truck .............................................................................................................................26
Pre-Delivery ...........................................................................................................................................................27
Adjust Timing for Automatic Engine Shut Down ............................................................................................28
Perform Pre-Delivery Inspection ...................................................................................................................... 28
Delivery on Operator .............................................................................................................................................28
Instructions Operating Manual ........................................................................................................................28
Instructions Daily Maintenance ....................................................................................................................... 28
Handing Over Truck ......................................................................................................................................... 28

This section is for the following models:

©2017 HYSTER COMPANY i

Table of Contents

ii
8000 SRM 2056 Series Code / Model Designation Reference Table

Series Code / Model Designation Reference Table

This table consist of the following Series Codes used
in this manual.

Series Code Model Designation Europe Model Designation America

A404 RS45-27CH, RS45-31CH RS45-27CH, RS45-31CH

General
This manual contains the information that is
WARNING required for transportation and reassembly of the
A404 Reachstacker. The information covers each
Read all the instructions contained in this manual
component that may have been disassembled for
before starting any work on the unit. Also read all
transportation purposes. Select the appropriate
procedures contained in the Operating Manual
assembly procedures accordingly.
before operating the truck. Make sure to check all
fluid levels and tire pressures before moving the
truck from the trailer.

1
Weights and Dimensions 8000 SRM 2056

Weights and Dimensions

A. WIDTH C. HEIGHT
B. LENGTH

Figure 1. Basic Truck Length, Width and Height

Table 1. Basic Truck

Model Length Width Height Weight
3,810 mm 39,100 kg
RS45-27 CH 8,660 mm (340.9 in.) 4,212 mm (165.8 in.)
(150 in.) (86,201 lb)
3,810 mm 42,100 kg
RS45-31 CH 8,660 mm (340.9 in.) 4,212 mm (165.8 in.)
(150 in.) (92,815 lb)
NOTE:
• Basic truck weight includes counterweight.
• Without counterweight the truck weighs 27,200 kg (59,965.7 lb).
• Weight tolerance is -600 / +1,500 kg (-1,300 / +3,300 lb).

2
8000 SRM 2056 Weights and Dimensions

A. WIDTH C. LENGTH
B. HEIGHT

Figure 2. Counterweight Length, Width and Height

Table 2. Counterweight
Model Length Width Height Weight
11,900 kg
RS45-27 CH
3,550 mm 2,278 mm 2,305 mm (26,235 lb)
(139.7 in.) (89.6 in.) (90.7 in.) 14,900 kg
RS45-31 CH
(32,849 lb)
NOTE: The weight includes the weight of the counterweight transport rack 655 kg (1,444 lb).

3
Weights and Dimensions 8000 SRM 2056

A. HEIGHT C. WIDTH
B. LENGTH

Figure 3. Boom Length, Width and Height

Table 3. Boom
Model Length Width Height Weight
RS45-27 CH 10,740 mm 2,136 mm 1,957 mm 15,080 kg
RS45-31 CH (422.8 in.) (84 in.) (77 in.) (33,245.7 lb)

A. LENGTH C. HEIGHT
B. WIDTH

Figure 4. Attachment Length, Width and Height

4
8000 SRM 2056 Loading Procedures

Table 4. Attachment
Model Length Width Height Weight
Non Powered Pile 6,042 mm 2,420 mm 1,993 mm 9,100 kg
Slope (237.8 in.) (95 in.) (78.4 in.) (20,062 lb)
6,042 mm 2,420 mm 2,330 mm 9,900 kg
Powered Pile Slope
(237.8 in.) (95 in.) (92 in.) (21,826 lb)

Loading Procedures
LOADING TRUCK ON A TRANSPORT
WARNING
Stay a safe distance from the edge of docks,
ramps, platforms, and other similar working
surfaces. Watch the "tail swing". Remember when
traveling in the forward direction and the steering
wheel is turned to move the lift truck away from
the edge of the dock, the rear will swing toward the
edge. This can cause the lift truck to fall off the
dock.
WARNING
IF THE LIFT TRUCK FALLS OFF THE DOCK, DO
NOT JUMP OFF! HOLD FIRMLY TO STEERING
WHEEL, BRACE YOUR FEET, AND LEAN
FORWARD AND AWAY FROM THE POINT OF
IMPACT.
Before the lift truck is moved on transport, check
the selected route to make sure there is enough
clearance for the lift truck as loaded on the
transport vehicle. Bridges, overpasses, power lines,
and natural barriers can prevent clearance.
Removal of the mast can be necessary.
If a trailer is the method of transportation, use
blocks in front and back of the trailer tires to
prevent movement of the trailer when the lift truck
is loaded and unloaded. If a loading ramp is used,
make sure that the ramp is the correct design and
capacity.
A crane can only be used to load or unload the lift
truck if the lift truck is equipped with lifting eyes.
Otherwise, the lift truck must be driven on or off the
transport.
LOADING DISASSEMBLED
COMPONENTS
1. Put blocks under the disassembled components
for stability during transport and to allow
loading and unloading with a fork lift. See
Figure 5 through Figure 6.
2. When lifting the components with slings and/or
hooks, attach these at the indicated lifting
points and/or lifting eyes. Make sure the lifting
device has the required capacity, see Figure 1
through Figure 4 for the weights of the
components.
3. Secure the components by connecting slings or
chains to the indicated tie down points on
Figure 5 through Figure 6 and the load surface
of the trailer.

5
Loading Procedures 8000 SRM 2056

1. TIE DOWN POINT

Figure 5. Lift Truck Tie Down Placement

1. SLING OR TIE DOWN POINT

Figure 6. Boom Tie Down Placement

1. SLING OR TIE DOWN POINT 2. WOODEN BLOCKS OR PALLETS

Figure 7. Attachment Tie Down Placement

6
8000 SRM 2056 Unloading Procedures

Unloading Procedures
UNLOADING TRUCK FROM TRANSPORT 3. Disconnect the slings or chains that secure the
truck to the trailer.
Lifting the Truck
To lift the basic truck without the boom, use the 4. Remove the wheel blocks.
lifting points and/or lifting eyes as indicated on
5. Check that all switches and accessories are
Figure 8. For the required capacity of the lifting
switched OFF.
devices, see Table 5.
6. Attach the lifting devices with required
1. If used, remove any protective cover.
capacity to the lifting points. When using
2. Make sure the parking brake is applied. lifting hooks always attach hooks to the lifting
points from inside to outside. See Figure 8.

1. LIFT TRUCK LIFTING POINTS ON FRAME

2. LIFT TRUCK LIFTING POINTS ON BOOM TOWER
3. COUNTERWEIGHT LIFTING POINTS, DO NOT USE FOR LIFTING TRUCK

Figure 8. Lift Truck Lifting Points

Table 5. Lift Truck Lifting Point Weights

Model Frame Lifting Points Weight Tower Lifting Points Weight
RS45 - 27 CH
11,741 kg (25,885 lb) 27,359 kg (60,316 lb)
RS45 - 31 CH

7
Moving and Towing
Driving On/Off a Trailer
When the truck will be driven from a trailer make
sure to have read and understood the Starting
Procedures as described in the Operating Manual.
1. Make sure the parking brake is applied.
2. Disconnect the straps or chains that attach the
truck to the trailer.
3. Remove the wheel blocks.
4. Start the truck, release the park brake and let
a assistant provide directions when driving off
the trailer.
5. Park the truck. Apply the hand brake and turn
the ignition OFF.
See the procedures under Moving a Disabled Truck
if the truck cannot be started and must be moved.
Moving and Towing
PRECAUTIONS
CAUTION
While the lift truck is being towed the engine must
stay running in order to generate sufficient
hydraulic oil pressure. Without hydraulic pressure
the steering system and service brake system do
not operate, and the park brake will automatically
apply. The parking brake can be manually released
if no hydraulic pressure is available.
CAUTION
Without oil pressure the transmission will be
damaged during towing. If the engine cannot run
during towing, remove the drive shaft between
transmission and drive axle.
WARNING
When the parking brake is manually released, the
lift truck does not have any parking brake function.
Block the wheels to prevent the lift truck from
moving. If the wheels are not blocked, serious
personal injury and damage to components can
occur.
8
8000 SRM 2056
See the procedures under
Adding Air Pressure to the Tires if air pressure in
one of the tires is less than 80% of the pressure as
indicated on the nameplate.
UNLOADING DISASSEMBLED
COMPONENTS
To lift the components from a transport either use a
fork lift or attach hooks and/or slings to the lifting
eyes and slinging points as indicated on Figure 5
through Figure 7.
For the required capacity of the lifting device. See
Figure 1 through Figure 4 for the weights of the
components.
Use blocks to support the component when
temporarily storing the component on the ground.
The blocks for the attachment must be high enough
to keep the twistlocks from the ground.
NOTE: If the parking brake is manually released, it
will need to be adjusted before the lift truck is
returned to service. With hydraulic pressure applied
to the parking brake, adjust play between brake
disc and park brake pads to 1.0 mm.
The parking brake caliper is mounted on a support
bracket which is mounted on the differential carrier
assembly. To manually release the parking brake,
perform the following procedures:
1. Place blocks on both sides (front and back) of
the drive tires to prevent movement of the lift
truck.
2. Loosen the lock nut.
3. Turn the adjustment bolt counterclockwise
until the brake disc is free.
4. Tighten the lock nut hand tight.
NOTE: After the parking brake has been manually
released, it will need to be adjusted before the lift
truck is returned to service.
8000 SRM 2056
1. ADJUSTING BOLT
2. LOCK NUT
Figure 9. Releasing the Parking Brake
MOVING A DISABLED TRUCK
WARNING
DO NOT tow the lift truck if a load is attached. Use
extra caution when moving a lift truck if any of the
following conditions exist:
• Brakes do not operate correctly.
• Steering does not operate correctly.
• Tires are damaged.
• Traction conditions are bad.
Moving and Towing
• The lift truck must be towed on a slope.
• If the engine cannot run, there is no power
assist available for the steering and service
brakes. This can make the control of the lift
truck difficult. Poor traction can cause the
disabled lift truck or towing vehicle to slide.
Steep grades will increase the required
brake effort.
WARNING
NEVER lift and move a disabled lift truck unless
the disabled lift truck MUST be moved and cannot
be towed.
1. Remove the drive shaft.
2. The towed lift truck must have an operator.
3. Tow the lift truck slowly.
4. If another lift truck is used to tow the disabled
lift truck, that lift truck must have an equal or
larger capacity than the disabled lift truck.
Install approximately half of a capacity load on
the forks of the lift truck that is being used to
tow the disabled lift truck. This half capacity
load will increase the traction of the lift truck.
Keep the load as low as possible.
5. Use a towing link made of steel that fastens to
both lift trucks. Connect the towing link to an
adequate provision, such as a towing pin or
lifting eye.
6. After towing is completed, place blocks on both
sides (front and rear) of all drive and steering
tires and re-apply the parking brake.
9
Truck Assembly 8000 SRM 2056

Truck Assembly
INSTALL LIGHTS ON BOOM 2. Install the working lights and connect the
Inner and Outer Boom Lights harness.
1. Reposition the beacon on the boom and connect Connectors from left to right: CPS193, CPS179,
with connector CPS 195 of the Boom Lights CPS173 and CPS192.
harness. See Figure 10.

1. CONNECTOR 4. WORKING LIGHT

2. BEACON 5. CONNECTORS
3. CAP SCREWS AND WASHERS 6. CAP SCREWS AND WASHERS

Figure 10. Lights on Boom

10
8000 SRM 2056 Truck Assembly

INSTALL COUNTERWEIGHT

WARNING
The counterweight is very heavy. Make sure that
the lifting device has the capacity to lift the
counterweight. See Table 2 for counterweight
weights.
Make sure no one is under or gets under the main
counterweight being moved.

1. Attach a lifting device to the two lift points of

the counterweight. When using lifting hooks,
attach hook from inside to outside. See
Figure 11.

2. Install the counterweight on the frame by

aligning the flange over the frame member.

3. Install the eight tie rods, washers, and nuts.

Tighten the top and rear tie rods to
1,500 N•m (1,106 lbf ft). See Figure 12.
(1,3) 1,500 N•m (1,106 lbf ft)
4. Connect the electrical connector between the
rear lights and the main wire harness, located 1. TOP TIE RODS
at the right side of the frame. 2. COUNTERWEIGHT
3. REAR TIE RODS

Figure 12. Counterweight Tie Rods

INSTALL BOOM AND DERRICKING

CYLINDERS
1. Measure distance A between the faces of the
boom bushings. See Figure 13

2. Measure distance B between the contact faces

of the inner supports on the boom tower.

3. Take distance B, deduct distance A plus the

required total play of 2 to 6 mm (1 to 3 mm on
each side).

4. See Table 6 to determine the total number of

required shims to be divided between the two
boom towers.

1. LIFT EYES 5. Use grease to glue the shims to the inside of

the inner tower bracket.
Figure 11. Counterweight Lifting Eyes

11
Truck Assembly 8000 SRM 2056

WARNING
The pin is heavy. Verify you have a stable ground
and use a personnel lift to prevent personal injury.

8. Prefill the inner diameter of the boom

mounting pins with about 1 liter of grease.

9. Lift the boom and align the bores of the boom

brackets with the bores in the boom towers.

10. Place the personnel lift at one side of the boom

tower.

11. Verify that sideward play between boom and

tower is between 1 and 3 mm when assembled.

12. Adjust the number of shims if required.

13. Use a tool to align the shims with the bores of

the boom and the tower.
A. DISTANCE BETWEEN FRAME
B. DISTANCE BETWEEN BUSHINGS 14. Install the pivot pin from the outside, towards
the center of the truck.
1. BOOM
2. BOOM BUSHING 15. From the center of the truck install the
3. BOOM TOWER retainer cap, washer and cap screw through the
pivot pin. See Figure 14.
Figure 13. Boom Shimming Measurements
16. Insert the bearing cap into the tower bore, and
Table 6. Boom Pivot Shimming install the washer and nut on the cap screw.
Distance in mm Shim Quantity
17. Torque the nut to 550 to 688 N•m (406 to 507
2–6 0 lbf ft).
6 – 10 2
18. Make sure that the three short cap screws are
10 – 14 4 installed on the support cap.
14 – 18 6
19. Move the personnel lift to the other boom tower
18 – 22 8 and repeat step Step 6 through Step 13 .
22 – 26 10
20. Disconnect the lifting device from the rear
6. Make sure that the conical faces of the boom lifting eyes of the boom.
tower and the mounting pins are free from
grease.

7. Connect a lifting device to lift the boom

assembly.

12
8000 SRM 2056 Truck Assembly

derricking cylinder can suddenly swing to the

horizontal position and can cause serious
personal injury.

21. Connect a tackle between the boom head and

the derricking cylinder.

22. Use the tackle to tilt the derricking cylinder

into position. Use the lifting device to lower the
boom as necessary. See Figure 15.

WARNING
The pin is heavy. Use a personnel lift to allow two
persons to insert the pin.

23. Move the personnel lift to the derricking

cylinder mounting position and make sure that
the spherical bearing in the derricking cylinder
aligns correctly both with the outer and the
inner bore of the boom bracket.

24. Install the pivot pin. Verify that the position of

the recess in the pivot pin allows assembly of
the securing plate.

25. Install the washer and cap screw from the

outside of the pivot pin.
(8) 550-688 N•m (406-507 lbf ft)
26. Install the ring, washer and nut on the cap
1. BUSHING screw and torque the nut to 1,100 N•m (812 lbf
2. LUBE FITTING ft).
3. CAP SCREW
4. WASHER
5. RETAINER CAP 27. Install the securing plate, two cap screws, and
6. PIN BOOM MOUNTING washers. Torque the cap screws to 320 N•m
7. SUPPORT CAP (236 lbf ft).
8. NUT
9. WASHER 28. Remove the tackle from the derricking cylinder
10. CAP SCREW
11. GREASE CAVITY and from the boom.

Figure 14. Boom to Frame Mounting
WARNING
Verify the chain lift has a lifting capacity of 2000 kg
(4410 lb) to lift the derricking cylinder or personal
injury may occur. Do not use the lifting eyes on the
derricking cylinder for removal and install. The
29. Move the personnel lift to the other derricking
mounting position and repeat Step 21 through
Step 27 .
30. Loosen the clamps around the air filter housing
and rotate the housing until the upper cover of
the pre-cleaner is in the horizontal position.
Retighten the clamps.

13
Truck Assembly 8000 SRM 2056

(2) 1,100 N•m (812 lbf ft) (6) 320 N•m (236 lbf ft)

A. SIDE VIEW SHOWN

1. RING 6. CAPSCREW
2. NUT 7. WASHER
3. WASHER 8. CAPSCREW
4. SECURING PLATE 9. PIVOT PIN
5. WASHER

Figure 15. Derricking Cylinder to Boom Mounting

14
8000 SRM 2056 Truck Assembly

31. Connect the hydraulic hoses and electrical INSTALL CONTAINER ATTACHMENT AND
connectors. See Figure 16. DAMPING CYLINDER
1. Remove the attachment pivot pins from the
boom.

2. Use a lift truck with a capacity of 15 ton to

position the attachment under the boom and
align the rotator frame with the boom. See
Figure 17.

3. Install the attachment pivot pins.

4. Install the locking plates and the cap screws

and tighten the cap screws to
320 N•m (236 lbf ft).

5. Remove the connecting bolts for the damping

cylinders.

6. Remove the straps from the damping cylinders

and rotate the cylinders downward.

7. Install the ball joint and spacer into the rod

end of the cylinder.

8. Align the rod end with the rotator frame and

insert the pin.
1. TELESCOPE HOSE - PORT B
2. TELESCOPE HOSE - PORT A
3. ATTACHMENT CONTROLS CONNECTOR 9. Install the washer and nut. Tighten the nut to
4. BOOM LIGHTS CONNECTOR 650-700 N•m (479-516 lbf ft). See Figure 18.
5. HOSE - P AUX
6. TELESCOPE HOSE - PORT D
7. HOSE - T AUX
8. TELESCOPE VALVE CONNECTOR
9. CABLE REEL CONNECTOR

Figure 16. Boom Hydraulic Hoses and Electrical

Connections

15
Truck Assembly 8000 SRM 2056

(4) 320 N•m (236 lbf ft)

1. BUSHING 4. CAPSCREW
2. PIVOT PIN 5. PLATE
3. GREASE FITTING

Figure 17. Boom to Rotator Frame Mounting

16
8000 SRM 2056 Truck Assembly

11. Remove and store the dust covers from the

electric connectors. Connect the 16-pole
connectors of the attachment to the connectors
of the boom harness.

(5) 650-700 N•m (479-516 lbf ft)

1. PIN
2. ROTATOR FRAME
3. DAMPING CYLINDER
4. WASHER
5. NUT
1. DRAIN HOSE
Figure 18. Damping Cylinder to Rotator Frame 2. HOSE P AUX
Mounting 3. HOSE T AUX
4. ATTACHMENT HARNESS CONNECTOR
10. Connect the hydraulic lines between the boom
Figure 19. Attachment Hydraulic Hoses and
and the rotator frame.
Electrical Connections

17
Truck Assembly 8000 SRM 2056

LUBRICATION This will take between 15 and 30 minutes after

the test button has been pushed.
Apply EP2/EP3 multipurpose grease to the
following items. See the Operating Manual for the 7. Turn the key switch into the OFF position.
location of these maintenance points.
8. Wipe excess grease.
Boom pivot to attachment 2 fittings
Dampening cylinder pivot pins 4 fittings
Boom pivot to frame 2 fittings

Automatic Greasing System (Optional)

1. Use a separate grease pump to apply grease
through a grease fitting at the mast pivots until
grease escapes at the mast hangers. Grease
will escape after having applied about 140 cc at
each mast pin.

2. Connect the grease lines of the optional

Automatic Greasing System at the mast
mounting and at the mast pivot pins.

3. Verify that the pump reservoir contains

sufficient grease.

4. Turn the key switch into the ON position.

5. Push the test button on the grease pump for

more than 6 seconds. The Automatic Greasing 1. GREASE PUMP
System will start and continue performing 2. TEST BUTTON
greasing cycles. See Figure 20.
Figure 20. Automatic Grease Pump
6. Establish that grease escapes from all points
connected.

18
8000 SRM 2056
General Checks After Assembly
PLUMBING CHECK
Check that all the hydraulic fittings, hoses, or tubes
have been correctly fastened and properly routed
(no scuffing and running over sharp edges). Verify
visually there are no leaks in the system. Correct
any discrepancies.
LUBRICATION CHECK
Check that all required grease points have sufficient
grease. For additional information, see the section
Periodic Maintenance 8000SRM2055.
FLUID LEVEL CHECK
Check all fluid levels. For additional information,
see the section Periodic Maintenance
8000SRM2055.
FUNCTIONALITY CHECK
Warm up the lift truck to approximately
80°C (176°F) and verify full functionality. Check
that all functions are working properly. Operate the
machine and test the brake, steering, and all the
hydraulic functions with and without load. Correct
any discrepancies. For additional information, see
the section Periodic Maintenance 8000SRM2055.
General Checks After Assembly
LITERATURE PACKAGE CHECK
Check content of standard literature package (may
deviate per market area). Be sure SPED literature
package is included. Deliver the literature package
to the maintenance people. Explain the purpose of
each item in the literature package. Explain where
this truck may deviate from the standard product.
CLEANING
It is also the dealer’s responsibility to deliver the
truck to the customer in a perfectly clean condition.
During transport and reassembly, grease, dust, and
oil will cover some parts of the machine making it
dirty or slippery. Degrease and clean the machine
completely. DO NOT steam clean the hoist chains!
LABELS
Check that all labels supplied by the factory are in
place at the correct location. Put the mast, truck,
and attachment labels in the correct position on the
truck after having cleaned and dried the location
where they will be fitted.
19
Pneumatic Tires and Wheels 8000 SRM 2056

Pneumatic Tires and Wheels

REMOVE WHEELS FROM LIFT TRUCK
WARNING
WARNING Lift truck wheels are heavy and can cause
personal injury.
The type of tire and tire pressure are shown on the
nameplate. Make sure the nameplate is correct for 3. Remove the wheel nuts and remove the wheel
the type of tires on the lift truck. from the lift truck. Be careful NOT to damage
Wheels and tires must be changed and repaired by the studs when removing the wheels.
trained personnel only.
4. Use a tire jack to remove the wheel assembly.
Always wear safety glasses.
Always use a tire inflator with a clip-on chuck
when deflating or adjusting the tire pressure. The
tire inflator must be equipped with a pressure
gauge and a hose of at least 3 m (10 ft) length.
During deflation or when adjusting the tire
pressure, the technician must not stand in-line
with the axis of the wheel. See Figure 21.
Adjusting tire pressure is allowed only if residual
air pressure exceeds 80% of the pressure as
indicated on the nameplate.
If the tire is removed from the truck and flat on the
ground, the technician should not have any body
part within the diameter of the tire when adjusting
the tire pressure. See Figure 22.
Wheels can explode and cause injury or death if 1. ACCURATE IN-LINE PRESSURE GAUGE
the above procedures are not followed.
Figure 21. Adjusting and Deflating Position

CAUTION
Lift truck wheels are very heavy, use caution when
removing wheels or personal injury may occur.

1. Raise the lift truck as described in Periodic

Maintenance 8000SRM2055, Putting a Lift
Truck on Blocks.

2. Attach a tire inflator as described above. Note

tire pressure. After air is drained from tire,
check the tire pressure to ensure there is no
residual pressure. Remove chuck. Remove the
tire stem valve core. Push a wire through the 1. HOSE LONG ENOUGH FOR USER TO STAND
valve stem to make sure that the stem does not OUTSIDE POTENTIAL TRAJECTORY OF
have a blockage causing a flow restriction. For EXPLOSION
dual tires, remove air pressure from both tires
using the described procedure before loosening Figure 22. Adjusting Tire Pressure Position
the wheel nuts.

20
8000 SRM 2056 Pneumatic Tires and Wheels

REMOVE TIRE FROM WHEEL

NOTE: This series of lift trucks uses one type of side flange locking, which is used for both 25 and 33 inch
pneumatic tires. See Figure 23.

WARNING
Completely remove the air pressure from the tire before it is removed from the lift truck. If dual wheels are
installed, remove the air from both tires. Air pressure in the tires can cause the tire and rim to explode
causing serious injury or death.

WARNING
Keep tire tools in firm contact with the wheel parts. If the tool slips, it can move with enough force to
cause serious injury. See Figure 23.

A. STEER WHEEL B. DRIVE WHEEL

1. TIRE 8. FLANGE SEAT

2. WHEEL NUT 9. LOCK RING
3. RIM CLAMP 10. O-RING
4. WHEEL HUB 11. 28° BEVEL
5. WEDGE BAND 12. WHEEL RIM
6. SPACER 13. KINGPIN
7. SIDE FLANGE

Figure 23. Wheel Arrangement

21
Pneumatic Tires and Wheels 8000 SRM 2056

1. DRIVER KEY
2. FLANGE SEAT
3. RIM

Figure 24. Wheel Driver

Tire Removal
STEP 1.
Use a press to loosen the tire from the side
flange. Remove the driver key when installed.
Remove the lock ring. See Figure 24.

STEP 2.
Push the flange seat together with the side
flange downward and remove the seal ring.

22
8000 SRM 2056 Pneumatic Tires and Wheels

STEP 3.
Remove the side flange and flange seat.

STEP 4.
Loosen the tire from the other side of the wheel
rim. Remove the rim from the tire.

INSTALL TIRE ON WHEEL

NOTE: This series of lift trucks uses one type of side flange locking, which is used for both 25 and 33 inch
pneumatic tires. See Figure 23.

Tire Installation

WARNING
The type of tire and the tire pressure (pneumatic
tires) are shown on the Nameplate. Make sure the
Nameplate is correct for the type of tires on the lift
truck. If the truck is equipped with bias-ply tires,
the ply rating listed on the Nameplate is the
minimum ply rating that must be installed. Tires
with ply ratings greater than or equal to the
Nameplate listed ply rating may be acceptable.
Check with your Hyster dealer whether a specific
bias-ply tire is approved for use on Hyster trucks.

WARNING
Not all makes of radial tires have sufficient
sidewall strength for successful use on forklift
trucks. This can affect stability and ride quality.
Check with your Hyster dealer whether a specific
radial tire is approved for use on Hyster trucks.

23
Pneumatic Tires and Wheels 8000 SRM 2056

WARNING
Wheels can explode and cause injury or death if
the following procedures are not followed:
• Clean and inspect all parts of the wheel
before installing the tire.
• Inspect all wheel components for
deformation, corrosion and fractures.
• Look for fractures at the contact area
between tire and wheel parts in particular.
• Unacceptable deformation includes
progressed wear, buckling, twisting or
presence of dents.
• Discard all wheel components showing any
of the above defects, and replace by new
ones.
• DO NOT use any damaged or repaired wheel
parts.
• Make sure that all parts of the wheel are the
correct parts for that wheel assembly.
• DO NOT mix parts between different types
or manufacturers of wheels.
• DO NOT mix types of tires, type of tire tread,
or wheel assemblies of different
manufacturers on any one lift truck.
• Check with your dealer whether a apecific
tire is approved for use on this truck.
Do not use a steel hammer on the wheel. Use a
rubber, lead, plastic, or brass hammer to put parts
together. Make sure that the lock ring is in the
correct position. The ends of the lock ring must
not touch. The clearance at the ends of the lock
ring will be approximately 8 to 15 mm (0.3 to
0.6 in.) after it is installed. If the clearance is
wrong, the wrong part has been used.

STEP 1.
Clean and inspect all parts of the wheel. If the
wheel has rust or corrosion, remove loose rust
and corrosion and paint the parts.

STEP 2.
Apply a rubber lubricant or a soap solution to
the tire bead and tube.

STEP 3.
Make sure that the wheel is the correct size for
the tire. Lubricate the part of the wheel that is
in contact with the bead.

24
8000 SRM 2056 Pneumatic Tires and Wheels

STEP 4.
Put the rim on blocks. Install the side flange.
Make sure the side flange is engaged with the
rim.

STEP 5.
Install the valve stem in the rim. Install the
tire on the rim.

STEP 6.
Install the flange seat and the side flange.
Align the brackets for the driver key on the rim
and the flange seat. See Figure 24.

STEP 7.
Push the flange seat down for access to the
groove for the seal ring. Install the seal ring.

STEP 8.
Install the lock ring. Make sure all parts are
correctly aligned. When correctly installed,
there will be a 8 to 15 mm (0.3 to 0.6 in.)
clearance between the ends of the side ring
and/or the lock ring. If removed, install the
driver in the lug. Add air pressure to the tire as
described in Adding Air Pressure to the Tires.

25
Pneumatic Tires and Wheels
ADDING AIR PRESSURE TO THE TIRES
WARNING
Add air pressure to the tires only in a safety cage.
Inflating or adjusting tire pressure outside of a
cage is allowed only if residual air pressure
exceeds 80% of the pressure as indicated on the
nameplate.
Inspect the safety cage for damage before use.
Always use a tire inflator with a clip-on chuck
when inflating or adjusting the tire pressure. The
tire inflator must be equipped with a pressure
gauge and a hose of at least 3 m (10 ft) in length.
During inflation the technician must stand away
from the safety cage. See Figure 25.
Do not use a hammer to try and correct the
position of the side flange or lock ring when the
tire has air pressure greater than 20 kPa (3 psi).
WARNING
Wheels can explode and cause injury or death if
the above procedures are not followed.
1. QUICK-RELEASE COUPLING
Figure 25. Adding Air Pressure to the Tire Position
26
8000 SRM 2056
1. Put the tire in a safety cage. See Figure 25.
2. Add 20 kPa (3 psi) of air pressure to the tire.
3. Check that all wheel parts are correctly
installed. Hit the side ring and/or lock ring
lightly to make sure that it is in the seat.
4. If installation is correct, add air pressure to the
tire. The correct pressure is shown on the
Nameplate.
5. Check that all wheel parts are correctly
installed. If installation is not correct, remove
all of the air pressure from the tire. Remove the
valve core to make sure all of the air pressure
has been removed and make adjustments. The
clearance at the ends of the lock ring will be 8
to 15 mm (0.3 to 0.6 in.) when the tire has the
correct air pressure.
INSTALL WHEELS ON LIFT TRUCK
Align and Install the wheel(s) and tire(s) on the
hub.
CAUTION
Check all wheel nuts after 2 to 5 hours of
operation, when new lift trucks begin operation,
and on all lift trucks when the wheels have been
removed and installed. Tighten the nuts as shown
in Figure 26. When the nuts stay tight for 8 hours,
the interval for checking the torque can be
extended to 250 hours.
Start with the wheel nut at the top and tighten the
nuts to 68 to 136 N•m (50 to 100 lbf ft) in the
sequence shown in Figure 26. Check to make sure
that the wheel(s) is tight against the hub.
Depending on your lift truck tighten the nuts to 420
to 440 N•m (310 to 410 lbf ft) for Kessler Drive
Wheel or 420 to 440 N•m (310 to 325 lbf ft) for
Drive Wheel Axle Tech.
8000 SRM 2056 Pneumatic Tires and Wheels

Figure 26. Wheel Nut Tightening Sequence for AxleTech Drive Wheel

A. INITIAL TORQUE VALUE

A. INITIAL TORQUE VALUE
B. RE-TORQUE VALUE
Figure 27. Wheel Nut Tightening Sequence Kessler
Drive Wheel with Dual Clamps
B. RE-TORQUE VALUE
Figure 28. Wheel Nut Tightening Sequence for
Steer Wheel with Single Clamps or Clamp Ring.

27
Pre-Delivery 8000 SRM 2056

Pre-Delivery
ADJUST TIMING FOR AUTOMATIC
ENGINE SHUT DOWN
The engine will automatically shut down 15
minutes after the operator has left the truck seat.
Verify which timing for engine shut down has been
ordered by the customer and adjust the timer
accordingly. The timer for empty seat engine shut
down is located inside the E-console at the right
side. See Figure 29 for its location. Adjust the relay
by turning the phillips screw that is visible through
the top cover of the relay.
The relay can be adjusted between 30 seconds in the
farthest anti-clockwise position and 15 minutes in
the farthest clockwise position. Never adjust the
shut down time to a value lower than 5 minutes to
make sure that the engine turbo will cool down
sufficiently before the engine is turned off
automatically. Measure and eventually re-adjust
the shut down time. Reposition the timer and close
the fuse cover.
1. ENGINE SHUT DOWN TIMER RELAY
PERFORM PRE-DELIVERY INSPECTION 2. ADJUSTMENT SCREW IN RELAY TOP COVER
Perform a Pre-delivery Inspection and complete the Figure 29. Engine Shut Down Timer Relay
Pre-delivery Inspection Report, per the ‘Dealer
Service Operation Manual’.

Delivery on Operator
INSTRUCTIONS OPERATING MANUAL HANDING OVER TRUCK
Ensure that the operator has read the Operating Stay together with the operator when the machine
Manual. Show the operator and maintenance is driven for the first time and provide guidance
people the location of all functions and explain their during those first steps.
purpose.

INSTRUCTIONS DAILY MAINTENANCE

Go over the daily checks with the driver. Repeat the
8-hour procedures together with the future driver in
order to ensure that he is aware of and has
understood those procedures.

28
 TECHNICAL PUBLICATIONS

8000 SRM 2056 8/17 (3/17)