Hyster RS45-27CH User manual

OPERATOR'S CAB
PART NO. 4186391 0100 SRM 2043

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.

©2018 HYSTER COMPANY
TABLE OF CONTENTS
Series Code / Model Designation Reference Table ................................................................................................ 1
General .....................................................................................................................................................................1
Description of Operation .........................................................................................................................................1
Cab Structure ...................................................................................................................................................... 1
Remove and Install ..................................................................................................................................................2
Cab Door Assembly ............................................................................................................................................. 3
Cab Door ...........................................................................................................................................................3
Remove ......................................................................................................................................................... 3
Install ........................................................................................................................................................... 3
Door Hinge ....................................................................................................................................................... 4
Remove ......................................................................................................................................................... 4
Install ........................................................................................................................................................... 4
Door Handle .....................................................................................................................................................4
Remove ......................................................................................................................................................... 4
Install ........................................................................................................................................................... 5
Door Latch ........................................................................................................................................................5
Remove ......................................................................................................................................................... 5
Install ........................................................................................................................................................... 6
Pedals ...................................................................................................................................................................6
Brake and Inching Pedal .................................................................................................................................6
Remove ......................................................................................................................................................... 6
Install ........................................................................................................................................................... 6
Accelerator Pedal and Sensor ......................................................................................................................... 7
Seat Assembly ......................................................................................................................................................7
Seat ...................................................................................................................................................................7
Remove ......................................................................................................................................................... 7
Install ........................................................................................................................................................... 8
Seat Cushion ....................................................................................................................................................8
Remove ......................................................................................................................................................... 8
Install ........................................................................................................................................................... 8
Back Cushion ...................................................................................................................................................9
Remove ......................................................................................................................................................... 9
Install ........................................................................................................................................................... 9
Boot Replacement ............................................................................................................................................9
Seat Suspension Replacement ........................................................................................................................ 9
Suspension Scissor and Shock Absorber Replacement ............................................................................... 10
Remove ....................................................................................................................................................... 10
Install ......................................................................................................................................................... 15
Compressor .................................................................................................................................................... 22
Remove ....................................................................................................................................................... 22
Install ......................................................................................................................................................... 27
Power Assist Armrest ........................................................................................................................................33
Release Cable .................................................................................................................................................33
Remove ....................................................................................................................................................... 33
Install ......................................................................................................................................................... 33
Gas Spring ..................................................................................................................................................... 34
Remove ....................................................................................................................................................... 34
Install ......................................................................................................................................................... 34
Joystick .......................................................................................................................................................... 34
Remove ....................................................................................................................................................... 34
Install ......................................................................................................................................................... 34
Armrest Rocker Switches ..............................................................................................................................35
Table of Contents
i

TABLE OF CONTENTS (Continued)
Remove ....................................................................................................................................................... 35
Install ......................................................................................................................................................... 35
Armrest Top Cover ........................................................................................................................................ 35
Remove ....................................................................................................................................................... 35
Install ......................................................................................................................................................... 35
Cab Fuse Panel ..................................................................................................................................................35
Override Key Switch ..................................................................................................................................... 35
Remove ....................................................................................................................................................... 35
Install ......................................................................................................................................................... 36
12V Power Socket .......................................................................................................................................... 37
Remove ....................................................................................................................................................... 37
Install ......................................................................................................................................................... 37
Climate Control Panel .......................................................................................................................................37
Air Recirculation Control Switch and Air Conditioning Switch ................................................................. 37
Remove ....................................................................................................................................................... 37
Install ......................................................................................................................................................... 37
Heater Control knob (Cable-Operated) ........................................................................................................ 38
Remove ....................................................................................................................................................... 38
Install ......................................................................................................................................................... 38
Information Display .......................................................................................................................................... 38
Remove ...........................................................................................................................................................38
Install ............................................................................................................................................................. 38
Steering Wheel and Column Assembly ............................................................................................................ 39
Steering Column ............................................................................................................................................39
Remove ....................................................................................................................................................... 39
Install ......................................................................................................................................................... 41
Adjustment Handle ....................................................................................................................................... 41
Remove ....................................................................................................................................................... 41
Install ......................................................................................................................................................... 41
Shift Lever and Turn Signal Lever ...............................................................................................................42
Remove ....................................................................................................................................................... 42
Install ......................................................................................................................................................... 42
Window Wipers ..................................................................................................................................................42
Window Wiper Assembly Replacement ........................................................................................................42
Remove ....................................................................................................................................................... 42
Install ......................................................................................................................................................... 42
Window Wiper Motor Replacement ..............................................................................................................42
Front Window Wiper Motor ...................................................................................................................... 42
Remove ................................................................................................................................................... 42
Install ..................................................................................................................................................... 43
Rear Window Wiper Motor Assembly .......................................................................................................... 43
Remove ....................................................................................................................................................... 43
Install ......................................................................................................................................................... 43
Top Window Wiper Motor Assembly ............................................................................................................ 44
Remove ....................................................................................................................................................... 44
Install ......................................................................................................................................................... 44
Window Washer System ................................................................................................................................... 44
Window Washer Reservoir and Pumps ........................................................................................................ 44
Remove ....................................................................................................................................................... 44
Install ......................................................................................................................................................... 45
Window Washer Hoses and Spray Nozzles ..................................................................................................45
Top Window Washer Hose and Spray Nozzle .......................................................................................... 45
Table of Contents
ii

TABLE OF CONTENTS (Continued)
Remove ................................................................................................................................................... 45
Install ..................................................................................................................................................... 45
Rear Window Washer Hose and Spray Nozzle ........................................................................................ 46
Remove ................................................................................................................................................... 46
Install ..................................................................................................................................................... 46
Front Window Washer Hose and Spray Nozzle ....................................................................................... 46
Remove ................................................................................................................................................... 46
Install ..................................................................................................................................................... 46
Window Replacement ........................................................................................................................................47
Cab Windows ................................................................................................................................................. 48
Remove ....................................................................................................................................................... 48
Install ......................................................................................................................................................... 48
Door Window ..................................................................................................................................................48
Remove ....................................................................................................................................................... 48
Install ......................................................................................................................................................... 48
Sliding Window Frame ..................................................................................................................................49
Remove ....................................................................................................................................................... 49
Install ......................................................................................................................................................... 49
Floor Mat ........................................................................................................................................................... 50
Remove ...........................................................................................................................................................50
Install ............................................................................................................................................................. 50
Roof Liner .......................................................................................................................................................... 50
Remove ...........................................................................................................................................................50
Install ............................................................................................................................................................. 51
Accessories ......................................................................................................................................................... 51
Mirror Replacement ...................................................................................................................................... 51
Map Light Replacement ................................................................................................................................51
Interior Fan Replacement .............................................................................................................................51
Sunshade Replacement ................................................................................................................................. 52
Top ..............................................................................................................................................................52
Rear ............................................................................................................................................................ 52
Training Seat ................................................................................................................................................. 52
Field Installation ....................................................................................................................................... 52
Remove ....................................................................................................................................................... 53
Label Replacement ............................................................................................................................................ 53
Checks and Adjustments ...................................................................................................................................... 53
Door Striker Pin Adjustment ............................................................................................................................53
Brake Pedal Adjustment ...................................................................................................................................54
Pedal and Sensor Adjustment for Braking and Inching ................................................................................. 55
Inching Sensor Calibration ...............................................................................................................................56
This section is for the following models:
Table of Contents
iii

"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS

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 SRM describes the functions of the cab and the
replacement instructions for the cab components.
See Figure 1. Some of the described components are
options that may not be present on each cab. The
operation of the various switches and controls can
be found in the Operating Manual.
The description and repair instructions for the
heater assembly are in Cab Heater and Air
Conditioner 0100SRM2044.
The remove and replace instructions for the cab as
an assembly are in the Frame and Main
Components 0100SRM2042.
Information on systems that are related to the cab
can be found in the SRM's:
•Electrical System 2200SRM2052
•Brake System 1800SRM2048
•Steering System 1600SRM2047
•Diagrams 8000SRM2058
Description of Operation
CAB STRUCTURE
The cab frame is a welded structure. The overhead
guard is an integral part of the cab frame. See
Figure 1. In order to maintain maximum overhead
protection do not make changes to the cab frame
and integrated overhead guard.
0100 SRM 2043 Series Code / Model Designation Reference Table
1

1. HEATER SECTION
2. ACCELERATOR PEDAL
3. BRAKE PEDAL
4. INCHING PEDAL
5. STEERING COLUMN
6. FRONT WIPER
7. CLIMATE PANEL
8. INFORMATION DISPLAY
9. LLMS INDICATOR
10. INTEGRATED OVERHEAD GUARD
11. ARMREST
12. TOP WIPER
13. AIR CONDITIONING ASSEMBLY
14. SEAT
15. REAR WIPER
16. E-CONSOLE
17. WINDOW WASHER FLUID RESERVOIR
Figure 1. Operator's Cab
Description of Operation 0100 SRM 2043
2

Remove and Install
Before making any repairs to the lift truck,
complete the following procedures:
•Place the lift truck on a solid, level surface.
•Retract and lower the boom completely.
•Place the shift lever in NEUTRAL.
•Apply the parking brake.
•Shut down the engine.
CAB DOOR ASSEMBLY
Cab Door
Remove
1. Open the sliding window.
2. Detach the gas spring.
3. Open the cab door as far as possible and
position the door at a 90° angle to the frame.
CAUTION
Use caution when lifting the cab door to avoid
damage to the cab frame.
4. Attach two lifting straps through the sliding
window opening. Place a cushion between the
sliding window frame and the lifting straps to
prevent damage.
1. DOOR HINGE
2. GAS SPRING
3. INNER DOOR HANDLE
4. STRIKER PIN
5. OUTER DOOR HANDLE
Figure 2. Cab Door
5. Lift the cab door out of the cab door hinges. See
Figure 2.
6. Move the cab door away from the lift truck and
place it on the ground.
7. Close the sliding window.
Install
1. Open the sliding window.
2. Attach two lifting straps through the sliding
window opening. Place a cushion between the
sliding window frame and the lifting straps to
prevent damage.
0100 SRM 2043 Remove and Install
3

3. Raise the cab door and place it in position
above the hinges.
4. Slowly lower the cab door until the cab door is
seated on the hinges.
5. Remove the lifting strap.
6. Make sure the cab door is moving properly on
the hinges.
7. If necessary, adjust the hinges. See Figure 3.
8. Make sure the door opens and closes correctly
and the locking system functions properly.
9. Attach the gas spring.
Door Hinge
Remove
1. Remove the cab door. See the section Cab Door.
2. Mark the location of the two hinges on the cab
frame.
3. Remove the six capscrews retaining the two
hinges to the cab frame and remove the two
hinges. See Figure 3.
1. DOOR HINGE
2. WASHER
3. CAP SCREW
4. THREAD
Figure 3. Door Hinge
Install
1. Position the two hinges to the cab frame as
marked and install the six capscrews strong
enough to hold the weight of the door, and loose
enough to allow alignment of the hinges.
2. Install the cab door. Refer to the section Cab
Door.
3. Align the door lock with the striker pin and
close the door.
4. Use a nylon hammer to move the lowest hinge
up until it supports the door.
5. Tighten al cap screws for the door hinges to
20 N•m (15 lbf ft).
Door Handle
Remove
1. Remove the plastic plug at the inside of the
door frame. See Figure 4.
Remove and Install 0100 SRM 2043
4