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