ASSEMBLY GUIDE

RS45-27CH, RS45-30CH, RS45-27IH, RS46-33CH,

RS46-30IH, RS46-36CH, RS46-33IH First Used
on 1563, 1566, 1567, 1568, 1570, and Up [A222]

PART NO. 1585698 8000 SRM 1175

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• 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 Mainte-
nance 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 condition that can cause immediate death or injury!

CAUTION
Indicates a condition that can cause property damage!
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 ............................................................................................. 1
Preparation of the Components Before Assembly............................................................................................ 2
Checking of the Wheels ..................................................................................................................................... 2
Air Pressure ................................................................................................................................................... 2
Drive Wheels ............................................................................................................................................. 3
Steer Wheels .............................................................................................................................................. 8
Wheel Nut Torque.......................................................................................................................................... 10
Preparation of the Extendable/Intermodal Container Attachment ................................................................ 12
Label Attachment .......................................................................................................................................... 12
Installation of the Extendable/Intermodel Container Attachment................................................................. 12
Install ............................................................................................................................................................. 12
General Procedures After Assembly ................................................................................................................. 13

This section is for the following models:

RS45-27CH, RS45-30CH, RS45-27IH, RS46-33CH, RS46-30IH, RS46-36CH,

RS46-33IH First Used on 1563, 1566, 1567, 1568, 1570, and Up [A222]

©2005 HYSTER COMPANY i

"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
8000 SRM 1175
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 14,000 kg
(30,865 lb).
• Cables or slings of sufficient capacity (see com-
ponents weight chart).
• Blocks of hard wood of various lengths, widths,
and thickness.
• A safety platform fastened on the Reach-
Stacker® carriage.
General Considerations Before Starting the Job
NOTE: This assembly guide is very extensive be-
cause it is written to cover all situations. Assembly
of new ReachStackers depends primarily upon how
the truck was transported and which carriage is
supplied. If the ReachStacker® was transported
overseas, it will be more disassembled than if only
shipped by land. Use the portions of the assembly
guide that meet your needs.
CAUTION
The following assembly procedures are for
assembling the ReachStacker after shipment
from the factory. Be sure to check all fluid
levels and tire pressures before removing the
ReachStacker 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
General Considerations Before Starting the Job
2. Tooling:
• A complete set of imperial and metric ring and
open-end spanners/wrenches.
• A torque wrench with a capacity up to 500 N•m
(approximately 370 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.
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.
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.
1
Checking of the Wheels
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.
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.
Checking of the Wheels
AIR PRESSURE
WARNING
Add air pressure to the tires only in a safety
cage. Check the nameplate of the Reach-
Stacker® for correct pressure, before inflating
the tires. Inspect the safety cage for damage
before use. When air pressure is added to the
tire, use a chuck that fastens onto the valve
stem of the inner tube. Verify there is enough
air hose to permit the operator to stand away
from the safety cage when air is added to the
tire.
WARNING
Do not sit or stand by the safety cage. Do not
use a hammer to try and correct the position of
2
8000 SRM 1175
7. It is recommended to perform all assembly pro-
cedures outside. During the carriage assembly,
the inner boom will be almost fully retracted.
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
the side flange or lock ring when the tire has
air pressure greater than 20 kPa (3 psi). When
the correct air pressure is reached, check that
all wheel parts are correctly installed. The
clearance at the ends of the lock ring will be
approximately 13 to 25 mm (0.5 to 1.0 in.) when
the tire has the correct air pressure.
Check air pressure of the wheels. See the nameplate
for correct air pressure of the tires. If the air pres-
sure is less than 80% of the pressure indicated on the
nameplate, remove the wheel after removing all air
from the tire and inflate it in a safety cage.
8000 SRM 1175 Checking of the Wheels

Drive Wheels

WARNING
Verify the jack, needed for the installation of the wheels, has a capacity equal to at least half the
weight of the ReachStacker. Refer to the nameplate for weight. The surface must be solid and
even. Tires and wheels must be changed and repaired by trained personnel only. Always wear
safety glasses, safety shoes, and gloves.

STEP 1.
Put blocks on each side (front and back) of the steer
tires to prevent movement of the ReachStacker.

1. DRIVE TIRES
2. STEER TIRES

STEP 2.
Fully lower and retract the boom.

STEP 3.
Put additional blocks under the frame behind the drive tires.

STEP 4.
If the hydraulic system will not operate, use a hydraulic jack under the side of the frame near the drive axle.
Verify the jack has a capacity of at least half the weight of the ReachStacker. See the nameplate.

3
Checking of the Wheels 8000 SRM 1175

WARNING
Deflate tires before removing the wheel from the ReachStacker. Air pressure in the tires can cause
the tire and rim parts to explode, causing serious injury or death. Always wear safety glasses.
Never loosen the nuts that hold the inner and outer wheel halves together when there is air pres-
sure in the tire.

WARNING
Always move wheels during assembly with a lifting device. Verify the lifting device has the correct
capacity for the parts being moved. Consult the specification chart for the weight of the parts.

STEP 5.
Completely remove the air pressure from the tires of
the driving wheels. Remove the 28 wheel nuts from
the hub, including the washers and the rim clamps.
Remove the wedgeband, the temporary spacer, outer
wheel, the wheel spacer, and the inner wheel from
the hub. The outer and inner wheel must be removed
by using a lifting device.

1. WEDGEBAND
2. TEMPORARY SPACER
3. WHEEL SPACER
4. EDGE WITH THE BEVEL

4
8000 SRM 1175 Checking of the Wheels

WARNING
Add air pressure to the tires only in a safety cage. Check the nameplate of the ReachStacker for
correct pressure, before inflating the tires. Inspect the safety cage for damage before use. When
air pressure is added to the tire, use a chuck that fastens onto the valve stem of the inner tube.
Verify there is enough air hose to permit the operator to stand away from the safety cage when air
is added to the tire.

WARNING
Do not sit or stand by the safety cage. 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). When the
correct air pressure is reached, check that all wheel parts are correctly installed. The clearance
at the ends of the lock ring will be approximately 13 to 25 mm (0.5 to 1.0 in.) when the tire has the
correct air pressure.

STEP 6.
Put the tire in a safety cage.

NOTE: Safety cage in use.

STEP 7.
Add air pressure to the tire. Verify the correct air pressure is in the tire. Check that all wheel parts are correctly
installed.

STEP 8.
Reassemble the inner wheel on the hub with a lifting device, verify the edge with the bevel is toward the outside
of the ReachStacker.

STEP 9.
Install the valve extension for the inner wheel and fasten it. Check for proper working order, by seeing if the
pressure indicator reacts on the pressure in the rim. If working properly, reassemble the wheel spacer on the
hub.

5
Checking of the Wheels 8000 SRM 1175

STEP 10.
To install the outer drive wheel, verify the edge with
the bevel is toward the inner drive wheel. Also ver-
ify that the outer notch in the wheel spacer aligns
with the edge with the bevel on the wheel rim. In-
stall the outer drive wheel on the hub with a lifting
device. Verify the valve stem aligns with the notch in
the rim.

1. EDGE WITH THE BEVEL

2. NOTCH

CAUTION
Verify all the contact areas between the rim, the axle, and the spacers are clean and have a mini-
mum paint thickness.

STEP 11.
Install the wedgeband on the hub (see picture). Clamp the wedgeband on the hub with the rim clamps including
spacers and wheel nuts. Fasten the wheel nuts. Be sure the rim clamps are well positioned on the wedgeband,
because the wedgeband locks up the rim on the hub.

1. WEDGEBAND 3. HUB SIDE

2. RIM CLAMP 4. WEDGEBAND SIDE

6
8000 SRM 1175 Checking of the Wheels

WARNING
When the wheels have been installed, check all wheel nuts after 2 to 5 hours of operation. Tighten
the nuts to the correct torque again. When the nuts stay tight after an 8-hour check, the interval
for checking can be extended to 250 hours.

CAUTION
Insufficient mounting torque can cause rim slippage, resulting in broken valves, worn parts, and
damaged tires. Excessive mounting torque can cause damage by stripping studs, collapsing spacer
band, or forcing rims out of round.

NOTE: Do STEP 12 a minumum of two times.

STEP 12.
Verify the tires are not touching the ground. Tighten
the wheel nuts in the correct sequence. First tighten
the wheel nuts to 35 N•m (26 lbf ft), then tighten to
100 N•m (74 lbf ft). Finally tighten the wheel nuts
to 405 and 440 N•m (300 and 325 lbf ft).

NOTE: Correct sequence of torquing the driving

wheels.

STEP 13.
Lower the ReachStacker, and then remove the hydraulic jack.

STEP 14.
Remove the wooden blocks in front and behind the steer tires.

STEP 15.
Follow the same procedure, STEP 1 through
STEP 13, for the drive wheel on the other side, when
required.

NOTE: Driving wheel reassembled.

7
Checking of the Wheels 8000 SRM 1175

Steer Wheels
STEP 1.
Apply the parking brake. Put blocks on both sides
(front and back) of the drive tires to prevent move-
ment of the ReachStacker.

1. DRIVE TIRES
2. STEER TIRES

STEP 2.
Fully lower and retract the boom.

WARNING
Verify the jack, needed for the installation of the wheels, has a capacity equal of at least 2/3 of the
weight of the ReachStacker. Refer to the nameplate for weight. The surface must be solid and
even. Tires and wheels must be changed and repaired by trained personnel only. Always wear
safety glasses, safety shoes, and gloves.

STEP 3.
Use a hydraulic jack to raise the steer tires.

STEP 4.
Put the hydraulic jack under the mounting pad of the steer axle to raise the ReachStacker. Raise the Reach-
Stacker so the steer tire is just above the surface. Put additional blocks of wood under the frame to support
the ReachStacker so the ReachStacker is stable.

WARNING
Deflate tires before removing the wheel from the ReachStacker. Air pressure in the tires can cause
the tire and rim parts to explode, causing serious injury or death. Always wear safety glasses.
Never loosen the nuts that hold the inner and outer wheel halves together when there is air pres-
sure in the tire.

WARNING
Always move wheels during assembly with a lifting device. Verify the lifting device has the correct
capacity for the parts being moved. Consult the specification chart for the weight of the parts.

STEP 5.
Completely remove the air pressure from the tires of the steer wheels. Remove the 24 wheel nuts from the hub,
including the washers and the rim clamps.

8
8000 SRM 1175 Checking of the Wheels

WARNING
Add air pressure to the tires only in a safety cage. Check the nameplate of the ReachStacker for
correct pressure, before inflating the tires. Inspect the safety cage for damage before use. When
air pressure is added to the tire, use a chuck that fastens onto the valve stem of the inner tube.
Verify there is enough air hose to permit the operator to stand away from the safety cage when air
is added to the tire.

WARNING
Do not sit or stand by the safety cage. 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). When the
correct air pressure is reached, check that all wheel parts are correctly installed. The clearance
at the ends of the lock ring will be approximately 13 to 25 mm (0.5 to 1.0 in.) when the tire has the
correct air pressure.

STEP 6.
Add air pressure to the tire. Verify for correct air pressure, see the nameplate. Check that all wheel parts are
correctly installed.

NOTE: Verify the edge with the bevel is toward the outside of the truck.

STEP 7.
Reassemble the wheel on the hub with a lifting device.

STEP 8.
Reassemble the wheel spacer on the hub.

CAUTION
Verify all the contact areas between the rim, the axle, and the spacers are clean and have a mini-
mum paint thickness.

STEP 9.
Install the steer wheel on the hub with a lifting device.

STEP 10.
Install the rim clamp on the hub. Clamp the O-ring and lock ring on the hub with the rim clamps including
spacers and wheel nuts. Fasten the wheel nuts. Verify the rim clamps are well positioned on the hub.

9
Checking of the Wheels 8000 SRM 1175

WARNING
When the wheels have been installed, check all wheel nuts after 2 to 5 hours of operation. Tighten
the nuts to the correct torque. When the nuts stay tight after an 8-hour check, the interval for
checking can be extended to 250 hours.

CAUTION
Insufficient mounting torque can cause rim slippage, resulting in broken valves, worn parts, and
damaged tires. Excessive mounting torque can cause damage by stripping studs, collapsing spacer
band, or forcing rims out of round.

NOTE: Complete STEP 11 at least twice.

STEP 11.
Verify the tires are not touching the ground. Tighten
the wheel nuts in the correct sequence. First tighten
the wheel nuts to 35 N•m (26 lbf ft), then tighten to
100 N•m (74 lbf ft). Finally tighten the wheel nuts
to 128 to147 N•m (94 to 108 lbf ft).

NOTE: Correct sequence of torquing the steer wheels.

STEP 12.
Lower the ReachStacker and remove the hydraulic jack.

STEP 13.
Remove the wooden blocks in front and behind the drive tires.

STEP 14.
Follow the same procedure, STEP 1 through STEP 12, for the steer wheel on the other side, when required.

WHEEL NUT TORQUE

STEP 1.
Check the wheel nut torque of each wheel. When the wheel nut torque for one or more wheels are not correct,
the wheel nut torque must be adjusted. Do the torque adjustment at least two times.

10
8000 SRM 1175 Checking of the Wheels

WARNING
Verify the jack needed for lifting one side of the ReachStacker has a capacity equal to at least half
of the weight of the ReachStacker. Refer to the nameplate for the correct weight. The surface must
be solid and even. Always wear safety glasses, safety shoes, and gloves.

WARNING
When the wheels have been installed, check all wheel nuts after 2 to 5 hours of operation. Tighten
the nuts to the correct torque. When the nuts stay tight after an 8-hour check, the interval for
checking can be extended to 250 hours.

STEP 2.
Put blocks in front and behind each tire that will remain on the ground. Put a jack under the mounting pad of
the axle and lift one side of the ReachStacker (the opposite side). Raise the ReachStacker so the tires are just
above the surface. Put additional blocks under the frame to support the ReachStacker so the ReachStacker is
stable.

STEP 3.
Verify the tires are not touching the ground. Tighten
the wheel nuts in the correct sequence until the
torque indicated has been reached. The torque for
drive wheels is between 405 to 440 N•m (300 to
325 lbf ft). The torque for the steer wheels is be-
tween 128 to147 N•m (94 to 108 lbf ft).

NOTE: Correct sequence of torquing the drive wheels.

NOTE: Correct sequence of torquing the steer wheels.

STEP 4.
Lower the ReachStacker, and then remove the hydraulic jack. Remove the blocks in front and behind the tires.

11
Installation of the Extendable/Intermodel Container Attachment 8000 SRM 1175

Preparation of the Extendable/Intermodal Container Attachment

LABEL ATTACHMENT
STEP 1.
Attach the truck label to the left and right side of the attachment.

STEP 2.
Attach the no one under the mast warning label to
the left and right outside of the attachment.

1. TRUCK LABEL
2. NO ONE UNDER THE MAST WARNING LABEL

Installation of the Extendable/Intermodel Container Attachment

INSTALL
WARNING
Verify any lifting devices have the correct ca-
pacity for the parts being moved. Consult the
specification chart for the weight of the con-
tainer attachment.
4. Install the two mounting pins through the brack-
ets.
5. Shut OFF the engine.
6. Together with the two spacers, install the cylin-
der pin and the two lock rings at the piston side
of the dampening cylinder.

1. Start the engine.

2. Position the boom tip above the container attach-
ment.
3. Raise the attachment with a lifting device. Align
the holes in the brackets on the attachment with
the holes in the brackets on the boom tip.
WARNING
Verify the attachment is correctly fastened to
the boom tip before removing the lifting device.
7. Remove caps and connect the hydraulic lines to
the attachment.

12
8000 SRM 1175
8. Lubricate the contacts of the two electrical con-
nectors with electrical grease. Plug the two male
connectors in the female connectors bolted on the
boom.
9. Start the engine and move the attachment from
the container.
10. Operate all the controls for the attachment.
Verify the controls operate the correct hydraulic
function as shown on the labels of the instru-
ment panel. Those checks must be done with and
without load. See the Operating Manual for
General Procedures After Assembly
1. The factory may have applied a protective layer
on the ReachStacker®. This layer can be removed
with a water-soluble degreaser and a high-pres-
sure gun with warm water.
2. New trucks must be inspected before delivery to
the customer. Perform the listed inspections and
complete the boxes on the PDI (pre-delivery in-
spection) report. For further explanation see the
dealer service operations manual. Return the
completed PDI report to the following:
General Procedures After Assembly
the correct operation of the hydraulic controls.
Check the operation of the indicator lights and
the twist lock flags, and also check lift and lower
interrupt function. Correct any malfunction.
WARNING
Do not try to locate hydraulic leaks by putting
hands on pressurized hydraulic components.
Hydraulic oil can be injected into the body by
pressure.
11. Check for leaks.
For Europe:
Nacco Materials Handling Group BV
Attn: P.Q.I.P. Coordinator
Nijverheidsweg 29
6541 CL Nijmegen
The Netherlands
13
 NOTES

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

14
 TECHNICAL PUBLICATIONS

8000 SRM 1175 3/05 Printed in United Kingdom