FRAME

RS45-27CH, RS45-31CH, RS46-36CH,

RS45-24IH, RS45-28IH, RS46-33IH
(HR45-27CH, HR45-31CH, HR45-36CH) [B222]

PART NO. 1625947 100 SRM 1252

 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 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.
Frame Table of Contents

TABLE OF CONTENTS

General ............................................................................................................................................................... 1
Description ......................................................................................................................................................... 1
Counterweight Repair ....................................................................................................................................... 2
General ........................................................................................................................................................... 2
Remove ........................................................................................................................................................... 2
Install ............................................................................................................................................................. 4
Covers ................................................................................................................................................................. 5
Remove ........................................................................................................................................................... 5
Install ............................................................................................................................................................. 5
Floor Plates, Handrails, and Steps ................................................................................................................... 6
Hydraulic Tank Repair ...................................................................................................................................... 7
Remove ........................................................................................................................................................... 7
Repair ............................................................................................................................................................. 9
Small Leaks ............................................................................................................................................... 9
Large Leaks ............................................................................................................................................... 9
Clean .............................................................................................................................................................. 9
Steam Method............................................................................................................................................ 9
Chemical Solution Method........................................................................................................................ 10
Other Methods of Preparation for Repair .................................................................................................... 10
Install ............................................................................................................................................................. 10
Suction Screen and Inspection Cover ........................................................................................................... 11
Remove....................................................................................................................................................... 11
Clean and Inspect...................................................................................................................................... 11
Install ......................................................................................................................................................... 11
Fuel Tank Repair ............................................................................................................................................... 12
Remove ........................................................................................................................................................... 12
Repair ............................................................................................................................................................. 13
Install ............................................................................................................................................................. 13
Exhaust System Repair ..................................................................................................................................... 15
Remove ........................................................................................................................................................... 15
Install ............................................................................................................................................................. 16
Cab Repair.......................................................................................................................................................... 17
Rear Cab Assembly........................................................................................................................................ 17
Bottom Cab Assembly ................................................................................................................................... 18
Cab Repair ..................................................................................................................................................... 18
Remove....................................................................................................................................................... 18
Install ......................................................................................................................................................... 19
Engine Repair .................................................................................................................................................... 20
Remove ........................................................................................................................................................... 20
Install ............................................................................................................................................................. 22
Label Replacement............................................................................................................................................. 23

This section is for the following models:

RS45-27CH, RS45-31CH, RS46-36CH, RS45-24IH, RS45-28IH, RS46-33IH

(HR45-27CH, HR45-31CH, HR45-36CH) [B222]

©2011 HYSTER COMPANY i

"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
100 SRM 1252 Description

General
This section has the description and repair proce- See Stabilizer 2120 SRM 1361 for description, oper-
dures for the lift truck frame and connected parts. In- ation, and repair information of components for the
cluded in this section are the frame, counterweight, stabilizer.
covers, floor plates, handrails and steps, hydraulic
tank, and fuel tank. The instructions for removal
and installation of the engine are also included in
this section.

Description
The frame is a one-piece weldment and has mounts axles, hydraulic and fuel tanks, operator’s compart-
for the main counterweight, engine, transmission, ment, and other parts. See Figure 1.

1. MAIN FRAME 6. STEER AXLE MOUNT

2. VALVE-PLATE MOUNT 7. MAIN COUNTERWEIGHT MOUNT
3. BOOM DERRICKING CYLINDER MOUNT 8. FUEL/HYDRAULIC TANK MOUNT
4. ENGINE/TRANSMISSION MOUNT 9. DRIVE AXLE MOUNT
5. BOOM MOUNT

Figure 1. Frame

1
Counterweight Repair 100 SRM 1252

Counterweight Repair
GENERAL
The shape of the main counterweights is the same, however, the weight will be different for each model. The
model weights are shown in Table 1.

Table 1. Counterweight Weights

Model Main Weight Additional

Weight
RS45-27CH, RS45-24IH, HR45-27 14,400 kg (31,747 lb) N/A
RS45-31CH, RS45-28IH, HR45-31 18,300 kg (40,352 lb) N/A
RS46-36CH, RS46-33IH, HR45-36 19,300 kg (42,549 lb) N/A
RS46-40CH, RS46-37IH, HR45-40 22,700 kg (50,054 lb) N/A
RS46-41S-CH, RS46-38S-IH, HR45-41S 23,800 kg (52,479 lb) N/A
RS46-41L-CH, RS46-38L-IH, 20,000 kg (44,100 lb) 3,150 kg (6,946 lb)
RS46-41LS-CH, RS46-38LS-IH,
HR45-41L, HR45-41LS

REMOVE 8. Put tags on the electrical wires for identification.

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

WARNING
The main counterweight is very heavy. Make
sure that the lifting device has the capacity to
lift the main counterweight. See Table 1 for
counterweight weights.
additional counterweight. See Figure 2.
10. Remove the four capscrews, nuts, and eight
washers that hold the additional counterweight
to the frame. See Figure 3.

1. Place truck on solid, level surface.

2. Lower the boom completely.

3. Shut down the engine.

4. Apply parking brake.

5. Disconnect the electrical connector between the

rear lights and the main wire harness, located at
the right side of the frame.

6. Put tags on the connectors for identification.

NOTE: Follow Step 7 through Step 12 when an addi- 1. LIFT POINTS

tional counterweight is attached.
Figure 2. Lift Points Additional Counterweight
7. Disconnect the electrical wire at the left and the
right rear light and remove the electrical wires
out of the counterweight and additional counter-
weight.

2
100 SRM 1252 Counterweight Repair

1. CAPSCREW
2. WASHER
3. NUT 1. LIFT POINTS
4. ADDITIONAL COUNTERWEIGHT
Figure 4. Lift Points Main Counterweight
Figure 3. Hardware for Additional
Counterweight

11. Carefully raise the additional counterweight

from the frame.

12. Lower the additional counterweight to the floor.

13. Put forks of another lift truck under the main

counterweight for support.

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

main counterweight. See Figure 4.

15. Remove the eight tie rods, washers, and nuts that
hold the main counterweight to the frame. See
Figure 5.

WARNING
Never lift the main counterweight straight up.
This will cause damage to the frame and may
cause personal injury.
1. TOP TIE RODS
16. Raise and move backward the main counter- 2. COUNTERWEIGHT
weight slowly at the same time. 3. REAR TIE RODS

17. Lower the main counterweight to the floor. Figure 5. Tie Rods

3
Counterweight Repair
INSTALL
1. Put the forks of a lift truck under the main coun-
terweight.
WARNING
The main counterweight is very heavy. Make
sure that the lifting device has the capacity to
lift the main counterweight. See Table 1 for
counterweight weights.
Make sure no one is under or gets under the
main counterweight being moved.
2. Attach a lifting device to the two lift points of the
main counterweight. See Figure 4.
3. Install the main counterweight on the frame by
aligning the flange over the frame member.
4. Install the eight tie rods, washers, and nuts.
Tighten the top and rear tie rods to 1500 N•m
(1106 lbf ft). See Figure 5.
5. Connect the electrical connector between the
rear lights and the main wire harness, located
at the right side of the frame.
4
100 SRM 1252
NOTE: Follow Step 6 through Step 10 when an addi-
tional counterweight is attached.
6. Attach a lifting device to the two lift points of the
additional counterweight. See Figure 2.
7. Install the additional counterweight to the
frame and align the flange with the main coun-
terweight.
8. Install the four capscrews, eight washers, and
nuts. See Figure 3. Tighten capscrews to
1500 N•m (1106 lbf ft).
9. Lead the electrical wires for the left and right
rear lights through the additional counterweight
and main counterweight.
10. Connect the electrical wires to the left and right
rear lights.
11. Start the engine and check if the left and right
rear light functions properly.
100 SRM 1252 Covers

Covers
REMOVE INSTALL
NOTE: The covers can be removed easily from the NOTE: If necessary, install the air cleaner and pre-
frame using a lock/unlock system. cleaner. See Figure 7.

1. Unlock the cover. See Figure 6. 1. Install the cover. See Figure 6.

NOTE: If necessary, remove the air cleaner and pre- 2. Lock the cover.
cleaner. See Figure 7.

2. Remove the cover.

1. PRECLEANER 3. COVERS
2. AIR CLEANER 4. FIXED COVERS

Figure 6. Covers

5
Floor Plates, Handrails, and Steps 100 SRM 1252

Legend for Figure 7

1. PRECLEANER 2. CLAMP

Figure 7. Precleaner

Floor Plates, Handrails, and Steps

The floor plates, handrails, and steps can be removed from the frame for access to components. See Figure 8.

Figure 8. Floor Plates, Handrails, and Steps

6
100 SRM 1252
Legend for Figure 8
1. STEPS
2. HANDRAILS
3. FLOOR PLATES
Hydraulic Tank Repair
The hydraulic tank is installed on the right side of
the frame. See Figure 9.
REMOVE
WARNING
The hydraulic oil tank contains 700 liter
(185 gal) of hydraulic oil. Drain the oil from
the tank before removing the hydraulic tank.
Failure to drain the tank could result in an oil
spill.
After use of the hydraulic system, the hy-
draulic oil is very hot. Do not begin any
maintenance procedures until the hydraulic
oil has cooled. Monitor the temperature of the
hydraulic oil by observing the temperature
gauge on the outside of the hydraulic tank.
1. Place truck on solid, level surface.
2. Lower the boom completely.
3. Shut down the engine.
4. Apply the brake.
5. Use a pan to catch the oil that is in the hydraulic
lines.
6. Disconnect the hoses at the shutoff valves.
7. Put caps in the open holes of the valves.
8. Close shutoff valves on bottom of hydraulic tank.
9. Remove the drain plug at the bottom of the tank
to drain the oil into clean barrels.
10. Disconnect the hydraulic lines at the bottom of
the hydraulic tank.
11. Disconnect the hydraulic return lines at the up-
per front of the hydraulic tank.
12. Use a pan to catch the oil that is in the hydraulic
lines.
Hydraulic Tank Repair
4. REAR FENDER
5. FRONT FENDER
13. Put tags on the lines for identification.
14. Put caps on the open lines and fittings.
CAUTION
These lift trucks have a 24-volt electrical
system (two 12-volt batteries in series). The
higher voltage can cause an electrical shock.
Always move battery disconnect switch to
disconnected position (pointer to left) before
working on electrical system.
For trucks with ECM (engine control module),
battery disconnect should only be performed
after switching OFF ignition for 30 seconds.
15. Disconnect all electrical connectors from the hy-
draulic tank and tag connectors to aid in the in-
stallation.
WARNING
Batteries are very heavy and should not be
lifted without assistance or personal injury
may occur.
16. Disconnect the cables from the batteries, and re-
move the batteries through the access door.
17. Remove handrails, walkway covers, and lower
step from the hydraulic tank.
18. Remove rear fender.
19. Attach a lifting device to the hydraulic tank at
the two lifting eyes.
20. Create tension on the chains.
21. Position the lifting device so hydraulic tank will
be moved a little toward the frame.
22. Remove the six capscrews holding hydraulic tank
to the frame.
7
Hydraulic Tank Repair 100 SRM 1252

WARNING CAUTION
The hydraulic tank weighs 600 kg (1323 lb). Verify the hydraulic hose and electrical cables
Verify the lifting device has the rated capacity are not damaged during the removal of the hy-
to remove the hydraulic tank. draulic tank.

23. Carefully lift the hydraulic tank from the lift

truck frame.

Figure 9. Hydraulic Tank Assembly

8
100 SRM 1252
Legend for Figure 9
1. COVER 4. COVER AND O-RING
2. BREATHER 5. SPRING
3. PLUG 6. FILTER
REPAIR
Small Leaks
NOTE: See the section Steam Method for prepara-
tions for leak repairs.
WARNING
Do not use tools that can make sparks, heat, or
static electricity. The vapors in the tank can
cause an explosion.
1. Use steam to clean the area around the leak. Re-
move all paint and dirt around the leak.
2. Apply Loctite 290® to the leak. Follow the in-
structions of the manufacturer.
Large Leaks
NOTE: See the section Steam Method for prepara-
tions for leak repairs.
1. Use acceptable welding practices to repair the
tank. See the American National Standard
Safety in Welding and Cutting AWS Z 49.1 -
1999.
CLEAN
WARNING
The power connect to the ECM (electronic con-
trol module) must be disconnected before weld-
ing on the vehicle. This is accomplished by dis-
connecting the 50-pin OEM interface connec-
tor. Ground for the welder must be located as
near as possible to the welding location. Never
attach the welder ground clamp to the ECM.
Special procedures must be followed when
large leaks or other repairs need welding or
cutting. All work must be done by authorized
personnel. If the tank is cleaned inside of a
building, make sure there is enough ventila-
tion. See the following manuals for additional
information:
• "Safe Practices for Welding and Cutting Con-
tainers That Have Held Combustibles" by the
American Welding Society, F4.1 - 1999.
Hydraulic Tank Repair
7. HYDRAULIC TANK
8. INDICATOR
9. INSPECTION COVER
• "Safety In Welding and Cutting," American
National Standard, AWS Z 49.1 - 1999.
When cleaning the tank, do not use solutions that
make dangerous gases at normal temperatures or
when heated. Wear device for the protection of the
eyes. Protect the body from burns.
When cleaning with steam, use a hose with a mini-
mum diameter of 19 mm (0.75 in.). Control the pres-
sure of the steam by a valve installed at the nozzle of
the hose. If a metal nozzle is used, it must be made of
a material that does not make sparks. Make an elec-
trical connection between the nozzle and the tank.
Connect a ground wire to the tank to prevent static
electricity.
Steam Method
1. Remove all the parts from the hydraulic tank,
except inspection cover.
2. Install the drain plug.
3. Fill the tank 1/4 full with a solution of water and
sodium bicarbonate or sodium carbonate. Mix
0.5 kg (1 lb) per 4 liter (1 gal) of water.
4. Mix the solution in the tank using compressed
air. Verify all the surfaces on the inside of the
tank are flushed with the solution.
5. Drain the tank.
6. Put steam into the tank until the tank does not
have odors and the metal is hot. Steam vapors
must come from all the openings.
7. Flush the inside of the tank with boiling water.
Verify all the loose material is removed from the
inside of the tank.
8. Make an inspection of the inside of the tank. If
it is not clean, repeat Step 6 and Step 7 and
make another inspection. When making inspec-
tions, use light that is approved for locations with
flammable vapors.
9. Put plugs in all the openings in the tank. Wait 15
minutes; then remove the inlet and outlet plugs.
9
Hydraulic Tank Repair
Test a sample of the vapor with a special indi-
cator for gas vapors. If the amount of flammable
vapors is above the lower flammable limit, repeat
the cleaning procedures.
Chemical Solution Method
NOTE: If the tank cannot be cleaned with steam, use
the following procedure:
1. Mix a solution of water and trisodium phosphate
or a cleaning compound with an alkali base. Fol-
low the instructions given by the manufacturer.
2. Fill the tank with the cleaning solution. Use com-
pressed air to mix the solution in the tank.
3. Drain the tank. Flush the inside of the tank with
hot (boiling) water. Make sure all the cleaning
compound is removed.
4. Make an inspection of the inside of the tank. If
the tank is not clean, repeat Step 1, Step 2, and
Step 3. Make another inspection of the tank.
When making inspections, use a light that is ap-
proved for locations with flammable vapors.
5. Check the tank for flammable vapors using a
special indicator for gas vapors. If the amount
of flammable vapors is not below the lower
flammable limit, repeat the cleaning procedures.
OTHER METHODS OF PREPARATION FOR
REPAIR
If nitrogen gas or carbon dioxide gas is available, pre-
pare the tank for welding using these gases. See the
manual Safe Practices for Welding and Cutting Con-
tainers That Have Held Combustibles by the Ameri-
can Welding Society, F4.1 - 1999. If these gases are
not available, another method using water can be
used as follows:
1. Fill the tank with water to just below the point
where the work will be done. Make sure the
space above the level of the water has a vent.
2. Use acceptable welding practices to repair the
tank. See the American National Standard
Safety In Welding and Cutting AWS Z 49.1 -
1999.
10
100 SRM 1252
INSTALL
WARNING
The hydraulic oil tank contains 700 liter
(185 gal) of hydraulic oil. Drain the oil from
the tank before removing the hydraulic tank.
Failure to drain the tank could result in an oil
spill.
1. Attach a lifting device to the hydraulic tank at
the two tank mounts.
2. Raise the hydraulic tank and put the hydraulic
tank in position on the frame.
3. Install the six capscrews that hold the hydraulic
tank to the frame.
4. Install lower step, walkway covers, and
handrails onto hydraulic tank.
5. Install rear fender onto hydraulic tank
6. Connect all electrical connectors as tagged dur-
ing removal.
WARNING
Batteries are very heavy and should not be
lifted without assistance or personal injury
may occur.
7. Install the batteries through the access door, and
connect the cables to the batteries.
8. Connect the hydraulic return lines located at the
upper front of the hydraulic tank.
9. Connect the hydraulic lines at the bottom of the
hydraulic tank.
WARNING
Before filling the hydraulic tank with hy-
draulic oil, replace the seal rings and gasket to
avoid oil leakage. See Figure 10.
10. Fill the hydraulic tank to the correct level with
the oil specified in the Maintenance Schedule ta-
ble in the section Periodic Maintenance 8000
SRM 1263.
100 SRM 1252 Hydraulic Tank Repair

NOTE: Remove suction screen by turning counter-

CAUTION clockwise.
Never start the engine with closed shutoff
valves. Open the shutoff valves before starting 5. Remove suction screen.
the engine to prevent damage to hydraulic
components. Clean and Inspect
11. Start the engine and operate the hydraulic sys- NOTE: Verify seal rings are in good condition. Re-
tem. Verify all functions work correctly. place, if necessary.

NOTE: Verify that the attached gasket on the inside

WARNING of the inspection cover is in good condition. Replace,
Do not try to locate hydraulic leaks by putting if necessary.
hands on pressurized hydraulic components.
Hydraulic oil can be injected into the body and 1. Clean seal rings.
cause personal injury.
NOTE: If condition of the suction screen is in doubt,
12. Check for leaks. replace suction screen.

13. Bleed the system. 2. Inspect suction screen.

SUCTION SCREEN AND INSPECTION Install

COVER NOTE: Only use seal rings specified by your lift truck
dealer. Using seal rings or washers other than spec-
Remove ified will lead to hydraulic oil leakage.
NOTE: To drain hydraulic oil from the tank, see Re- NOTE: Install suction screen by turning clockwise.
move, Step 9.
1. Install suction screen.
1. Drain hydraulic oil from the hydraulic tank.
2. Install inspection cover using seal rings and
2. Remove the bolts of the inspection cover. See Fig- bolts.
ure 10.
3. Tighten bolts to 51 N•m (38 lbf ft).
3. Remove seal rings.

4. Remove inspection cover.

11
Fuel Tank Repair 100 SRM 1252

1. HYDRAULIC TANK 4. SEAL RING (10)

2. SUCTION SCREEN 5. BOLT (10)
3. INSPECTION COVER 6. SHUTOFF VALVES

Figure 10. Suction Screen and Inspection Cover

Fuel Tank Repair

The fuel tank is installed on the left-hand frame
channel. See Figure 11.
REMOVE
1. Place truck on solid, level surface.
WARNING
When removing the fuel tank, do not use tools
that can make sparks, heat, or static electricity.
The vapors in the tank can cause an explosion
and personal injury may occur.

2. Lower the mast completely. 5. Put a drain pan under the fuel tank.

3. Shut down the engine. 6. Remove drain plug to drain the fuel from the
tank.
4. Apply the parking brake.

12
100 SRM 1252
WARNING
If the fuel is drained from the fuel tank, put the
fuel in a can or barrel that has a sealed cap to
prevent contamination.
7. Disconnect the fuel lines at the tank.
8. Remove handrails, walkway covers, and steps
from the fuel tank.
9. Remove rear fender.
CAUTION
These lift trucks have a 24-volt electrical
system (two 12-volt batteries in series). The
higher voltage can cause an electrical shock.
Always move battery disconnect switch to
disconnected position (pointer to left) before
working on electrical system.
10. Disconnect all electrical connectors from the fuel
tank and tag connectors to aid in the installation.
11. Attach a lifting device to the fuel tank at the two
tank mounts.
12. Create tension on the chains.
13. Position the lifting device so fuel tank will be
moved a little toward the frame.
14. Remove the six capscrews that hold fuel tank to
the frame.
WARNING
The fuel tank weighs 600 kg (1323 lb). Verify
the lifting device has the rated capacity to lift
the fuel tank.
15. Carefully lift the fuel tank from the lift truck
frame.
Fuel Tank Repair
REPAIR
WARNING
Do not use tools that can make sparks, heat, or
static electricity. The vapors in the tank can
cause an explosion.
Repair the fuel tank as described in the repair proce-
dures for the hydraulic tank.
INSTALL
1. Attach a lifting device to the fuel tank at the two
tank mounts.
WARNING
The fuel tank weighs 600 kg (1323 lb). Verify
the lifting device has the rated capacity to lift
the fuel tank.
2. Raise fuel tank and put in position on the frame.
3. Install the six capscrews that hold fuel tank to
the frame. Tighten to 51 N•m (38 lbf ft).
4. Install the steps, walkway covers, and handrails
to the fuel tank.
5. Install rear fender to the fuel tank.
6. Connect all electrical connectors as tagged dur-
ing removal.
7. Connect fuel lines to the tank.
8. Fill fuel tank to correct level with fuel specified
in the Maintenance Schedule of the section Peri-
odic Maintenance 8000 SRM 1263.
9. Start engine.
10. Check for leaks.
13
Fuel Tank Repair 100 SRM 1252

1. FUEL TANK 4. FILLER CAP

2. FUEL GAUGE SENDER 5. DRAIN PLUG
3. COVER

Figure 11. Fuel Tank Assembly

14
100 SRM 1252 Exhaust System Repair

Exhaust System Repair

REMOVE 1. Remove the top exhaust tube at the left side of
the frame. See Figure 12.
WARNING
Exhaust system must be at room temperature
before starting disassembly or personal injury
may occur.

1. TOP EXHAUST TUBE 4. MUFFLER

2. MOUNTING POINTS 5. FLEXIBLE EXHAUST TUBE
3. EXHAUST TUBE 6. TORQUE BAND CLAMPS

Figure 12. Exhaust

15
Exhaust System Repair 100 SRM 1252

NOTE: For easy access of the muffler assembly, turn 1. Install the exhaust tube elbow and flexible ex-
the steering wheel until the steering wheel spindle is haust tube to the engine (turbocharger) with
against the stop on axle to the left or right side. torque band clamps.

2. Remove the second top exhaust tube at the left 2. Install the exhaust tube from the muffler to the
side of the frame. flexible exhaust tube with torque band clamps.

3. Disconnect the exhaust tubes from the muffler. 3. Position the exhaust tube at the left side of the
frame.
4. Remove the muffler.
4. Position the muffler and install the exhaust
5. Remove the other exhaust tube at the left side of tubes to the muffler.
the frame.
5. Install the second top exhaust tube at the left
6. Remove the exhaust tube from the muffler to the side of the frame.
flexible exhaust tube.
6. Install the top exhaust tube at the left side of the
7. Remove the flexible exhaust tube and exhaust frame.
tube elbow from the engine (turbocharger).
7. Tighten all torque band clamps.
INSTALL
NOTE: To make repositioning possible, do not tighten
the clamps.

16
100 SRM 1252 Cab Repair

Cab Repair
REAR CAB ASSEMBLY NOTE: Interior covers are affixed with self-tapping
screws.
See Figure 13 for rear cab assembly.

1. COVER PLATE 6. REAR DUCT ASSEMBLY

2. FUSE SECTION 7. CONSOLE COVER
3. RELAY SECTION 8. CONSOLE TOP
4. FOAM COVER 9. INSTRUMENT PANEL
5. HEADLINER

Figure 13. Rear Cab Assembly

17
Cab Repair 100 SRM 1252

BOTTOM CAB ASSEMBLY that does not have the minimum capacity can
break causing the cab to drop and may result
See Figure 14 for bottom cab assembly. in serious personal injury.

CAUTION
Lift the operator’s cab carefully. Make sure
all wires and attachments are disconnected
and loose components are not obstructing the
movement.

1. Switch off engine.

2. Disconnect battery ground lead.

3. Remove the two front covers.

4. Remove four new bolts holding steering pump.

SeeFigure 15.

1. WIPER MOTOR ASSEMBLY

2. WIPER COUPLING
3. AIR FILTER
4. COVER PLATE
5. STEERING PUMP
6. EMERGENCY STOP

Figure 14. Bottom Cab Assembly

CAB REPAIR
Remove

WARNING
Before removing heater hoses, allow time for
heater hoses to cool down. Hot water may 1. STEERING PUMP HEX BOLTS
cause severe burns. 2. BRAKE VALVE BOLTS
3. STEERING PUMP
4. BRAKE VALVE
WARNING 5. EMERGENCY STOP
Do not disconnect the AC hoses. Discharging
Figure 15. Steering Pump and Throttle
and/or refilling of the refrigeration fluid may
Connections
only be performed by a trained and qualified
personnel.

WARNING
Make sure the lifting device has a minimum ca-
pacity to lift 1000 kg (2205 lb). A lifting device

18
100 SRM 1252 Cab Repair

5. Remove two bolts holding brake valve. 6. Tighten cab mounting bolts to 90 N•m (66 lbf ft).

6. Disconnect electrical cable. 7. Connect electrical cables, ground wire, hoses,

7. Disconnect electrical harnesses that are located
on the right of heater unit.
8. Disconnect window washer hoses and mark their
positions.
9. Remove three bolts and swing heater unit down.
10. Disconnect electrical connections, control cables,
and air duct from heater unit.
11. Disconnect hinge and remove heater unit.
12. Disconnect ground lead.
steering pump, and brake valve. Make sure that
all connections have been restored.
8. Mount heater unit to hinge. Connect control ca-
bles and electrical connections. Pivot unit up and
install with three bolts.
9. Connect declutch and throttle cables.
10. Install doors.
11. Connect battery ground lead.
12. Install the two front covers.

13. Remove four mounting bolts, two on left side and

two on right side of truck.

14. Remove cab doors before attaching a lifting de-

vice.

15. Connect a lift strap under overhead guard struc-

ture. Provide a cushion at top of door area to pre-
vent damage.

16. Carefully lift cab away from lift truck. Set cab as-
sembly in a suitable storage area and put blocks
under cab to stabilize and prevent damage.

17. Remove four rubber isolation mounts from frame

and inspect for damage. Reinstall or replace if
necessary.

Install
1. Connect lift strap under overhead guard struc-
ture. Provide cushion at top of door area to pre-
vent damage.

2. Make sure that insulators are in place. See Fig- 1. TOP OF INSULATOR
ure 16. 2. SPACER
3. BOTTOM OF INSULATOR
3. Lift operator’s cab. 4. REBOUND WASHER
5. WASHER
4. Carefully lower cab on insulators and make sure 6. CAPSCREW
that it is properly centered. Figure 16. Insulators
5. Mount cab with washers and bolts.

19
Engine Repair 100 SRM 1252

Engine Repair
REMOVE 15. Remove the fan.

16. Close shutoff valves on the bottom of the hy-

CAUTION draulic tank.
Battery disconnect should only be performed
at least 30 seconds after switching OFF igni- NOTE: Use a pan to catch the oil in the hydraulic
tion. lines.

Remove the engine as follows: 17. Disconnect the hydraulic lines at the pumps.

1. Place truck on solid, level surface. 18. Put tags on the lines for identification.

2. Lower the boom completely. 19. Put caps on open lines and fittings.

3. Shut down the engine. 20. Disconnect the flexible tube, attached to the en-
gine, from the exhaust pipe. See Figure 12
4. Apply parking brake.
21. Disconnect fuel lines at the fuel filter and engine.
CAUTION 22. Disconnect electric wires and wiring harnesses
Remove the ground cable first. from the engine.

5. Disconnect the cables at the battery. 23. Disconnect the starter cable from the starter.

24. Disconnect the electrical wires from the trans-

WARNING mission.
Verify the lifting device has the rated capacity
of 2500 kg (5512 lb). 25. Disconnect the cooling lines from the transmis-
sion.
6. Attach a lifting device and sling to the hood pan-
els. 26. Remove the U-joint from the transmission.

NOTE: Do not remove the hood panel located above 27. Disconnect hydraulic lines from the transmission
the air cleaner. to the hydraulic filter.

7. Remove the hood panels.

8. Remove the precleaner and pipe from the air

cleaner. See Figure 17.

9. Remove the hood panel located above the air

cleaner.

10. Remove the rubber elbow between the engine

and air cleaner.

11. Remove the air cleaner.

12. Drain the coolant from the cooling system.

NOTE: Do not disconnect the cooling lines from the

radiator.
1. PRECLEANER
13. Disconnect the cooling lines from the engine. 2. AIR CLEANER
3. ELECTRONIC RESTRICTION INDICATOR
14. Remove the capscrews to the fan through the in-
spection cover. Figure 17. Engine Air Cleaner

20
100 SRM 1252 Engine Repair

28. Put caps on the hydraulic lines. all the connections to the engine or transmission
have been removed.
29. Disconnect the charge air cooler lines from the
charge air cooler core on the radiator.

30. Disconnect the lines from the expansion tank.

31. Disconnect the drive shaft from the transmis-

sion.

WARNING
Verify the lifting device has the rated capacity
of at least 2500 kg (5512 lb) or personal injury
may occur.

32. Connect a lifting device to the engine and trans-

mission.

33. Remove the engine mount capscrews that hold

the engine mount at the fan end of the engine. 1. REAR MOUNT (FAN END OF ENGINE)
See Figure 18. 2. FRONT MOUNT
3. FRONT MOUNT CAPSCREW
34. Remove the front mount capscrews that hold the 4. ENGINE MOUNT CAPSCREW
two front mount brackets to the engine. See Fig-
ure 18. Figure 18. Engine Mounts

35. Carefully lift the engine and transmission as-

sembly from the frame. See Figure 19. Verify

1. DIPSTICK 5. COOLANT FILTER

2. ENGINE OIL FILL CAP 6. ENGINE OIL DRAIN PLUG
3. FUEL FILTER 7. ECM
4. OIL FILTER 8. ALTERNATIVE ENGINE OIL FILL

Figure 19. Engine Assembly Tier 3

21
Engine Repair
INSTALL
WARNING
Verify the lifting device has the rated capacity
of at least 2500 kg (5512 lb).
1. Connect a lifting device to the engine and trans-
mission.
2. Install the engine and transmission assembly in
the frame.
3. Install and tighten the nuts and bolts for the en-
gine mounts.
4. Connect the U-joint to the torque converter.
5. Tighten the bolts for the universal joint to
68 N•m (50 lbf ft).
6. Connect the lines to the expansion tank.
7. Connect the charge air cooler lines to the charge
air cooler core on the radiator.
8. Connect hydraulic lines from the transmission to
the hydraulic filter.
9. Connect the cooling lines to the transmission.
10. Connect the electric wires to the transmission.
11. Connect the starter cable to the starter.
12. Connect electric wires and wire harnesses to the
engine.
13. Install the fuel lines between the fuel filter on the
engine assembly and fuel tank and water separa-
tor.
14. Connect the flexible tube, attached to the engine,
from the exhaust pipe using a new pipe clamp.
15. Connect the hydraulic lines to the hydraulic
pumps.
CAUTION
Never start the engine with closed shutoff
valves. Open the shutoff valves before starting
22
100 SRM 1252
the engine to prevent damage to hydraulic
components.
16. Open the valves on the hydraulic tank.
17. Mount the fan to the engine.
18. Install the capscrews to the fan through the in-
spection cover.
19. Install the air cleaner.
20. Connect the rubber elbow between the engine
and air cleaner.
21. Connect the cooling lines to the engine.
22. Fill cooling system with coolant.
23. Connect the drive shaft to the transmission.
24. Check all oil levels.
CAUTION
Install the power cable first or lift truck dam-
age may occur.
25. Connect the cables to the battery.
26. Install the hood panel above the air cleaner.
27. Install the precleaner and pipe from the air
cleaner.
28. Start the engine and check for leaks and correct
operation.
WARNING
Verify the lifting device has the rated capacity
of 5512 kg (2500 lb).
29. Attach a lifting device and sling to the hood pan-
els.
30. Install the hood panels.
100 SRM 1252
Label Replacement
Changes in the size or number of drive tires will
change the capacity rating. See a dealer for Hys-
ter lift trucks for a replacement nameplate. The
nameplate information is a safety item and must be
correct.
WARNING
If labels that have warnings or cautions are
damaged, they must be replaced. See Fig-
ure 20.
1. Make sure the surface is dry and has no oil or
grease. Do not use solvent on new paint. Clean
the surface of old paint using a cleaning solvent.
Label Replacement
2. Remove the paper from the back of the label. Do
not touch the adhesive surface.
3. Carefully hold the label in the correct position
above the surface. The label cannot be moved
after it touches the surface. Put the label on the
surface. Make sure all air is removed from under
the label and the corners and edges are tight.
NOTE: If the labels or information plates are missing
or damaged, they must be replaced.
23
Label Replacement 100 SRM 1252

Figure 20. Label Positions

24
100 SRM 1252 Label Replacement

Legend for Figure 20

1. NO RIDERS LABEL 18. SLIP RESISTANT TREAD WARNING
2. US PATENTS AND TRADEMARKS LABEL 19. MAST WARNING LABEL
3. HYDRAULIC STOP SWITCH LABEL 20. HYSTER LABEL
4. COVER PLATE LABEL 21. HYSTER LABEL
5. PLASTIC RIVET 22. HYSTER LABEL
6. FAN WARNING LABEL 23. PINCH POINT LABEL
7. PARK BRAKE WARNING LABEL 24. HYSTER LABEL
8. ETHER WARNING LABEL 25. JOYSTICK LABEL
9. PARK BRAKE LABEL 26. OVERRIDE AND LOAD MOMENT LABEL
10. HYSTER LABEL 27. NAMEPLATE TAG
11. OPERATOR WARNING LABEL 28. NAMEPLATE LABEL
12. OPERATOR RESTRAINT LABEL 29. HYDRAULIC OIL FILL LABEL
13. DOOR RELEASE LABEL 30. FUEL FILL LABEL
14. BATTERY DISCONNECT LABEL 31. MODEL LABEL
15. ANTIFREEZE LABEL 32. LOAD CAPACITY LABEL
16. BORON-FREE ANTIFREEZE ONLY LABEL 33. OPERATING MANUAL LABEL
17. RADIATOR CAP WARNING

25
 NOTES

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 TECHNICAL PUBLICATIONS

100 SRM 1252 1/11 (7/07)(5/06) Printed in United Kingdom