Need help?Do you have a question about the Hyster RS45-31CH and is the answer not in the manual?
General safety precautions for maintenance and repair procedures.
Explains WARNING and CAUTION symbols and their meanings.
Lists Series Codes and corresponding Model Designations for the manual.
Outlines the scope of this SRM and references related service manuals.
Details the cab frame and integrated overhead guard construction.
Procedures for removing and installing cab door, hinges, handle, and latch.
Steps for removing and installing pedals, seat, seat cushion, and back cushion.
Guides for replacing boot, seat suspension, and scissor/shock absorber.
General safety precautions for maintenance and repair procedures.
Explains WARNING and CAUTION symbols and their meanings.
Lists Series Codes and corresponding Model Designations for the manual.
Outlines the scope of this SRM and references related service manuals.
Details the cab frame and integrated overhead guard construction.
Procedures for removing and installing cab door, hinges, handle, and latch.
Steps for removing and installing pedals, seat, seat cushion, and back cushion.
Guides for replacing boot, seat suspension, and scissor/shock absorber.
This document is a service manual for the Hyster Operator's Cab, providing detailed instructions for maintenance and repair of various components within the cab assembly. It is intended for use by trained and experienced technicians to ensure proper servicing and to maintain the safety and functionality of the lift truck.
The manual begins with crucial safety precautions that must be observed before undertaking any maintenance or repair work. These include ensuring the lift truck is on a solid, level surface, retracting and lowering the boom completely, placing the shift lever in NEUTRAL, applying the parking brake, and shutting down the engine. Technicians are advised to disconnect the battery connector for electric lift trucks or the battery ground cable for internal combustion lift trucks to prevent accidental operation or electrical hazards. The use of correct blocks to prevent the unit from rolling or falling is emphasized, with a reference to the "HOW TO PUT THE LIFT TRUCK ON BLOCKS" section in the Operating Manual or Periodic Maintenance. Maintaining a clean unit and working area, using correct and well-maintained tools, and always using HYSTER APPROVED parts are also highlighted as essential practices. The manual stresses that replacement parts must meet or exceed original equipment manufacturer specifications to ensure continued safety and performance. Before using force to remove parts, technicians must ensure all nuts, bolts, snap rings, and other fastening devices are removed. A "DO NOT OPERATE" tag must be fastened to the controls when repairs are in progress or if the unit requires repairs. Throughout the instructions, "WARNING" and "CAUTION" notes are used to indicate hazardous situations that could result in death, serious injury, minor injury, or property damage. The manual also includes specific warnings regarding flammable fuels (Gasoline, LPG, CNG, Diesel) and the flammable gas generated by batteries during charging, emphasizing the need for proper ventilation and keeping fire and sparks away from the area.
The "General" section of the manual provides an overview of the cab's functions and replacement instructions for its components. It notes that some described components may be optional and not present on every cab. For information on the operation of various switches and controls, technicians are directed to the Operating Manual. Instructions for the heater assembly are found in a separate document, "Cab Heater and Air Conditioner 0100SRM2044," while the removal and replacement of the cab as an assembly are detailed in "Frame and Main Components 0100SRM2042." Related systems such as the Electrical System, Brake System, Steering System, and Diagrams are referenced in other SRM documents.
The "Cab Structure" is described as a welded frame with an integrated overhead guard. The manual explicitly states that no changes should be made to the cab frame and integrated overhead guard to maintain maximum overhead protection. An illustration of the operator's cab highlights key components, including the heater section, accelerator pedal, brake pedal, inching pedal, steering column, front wiper, climate panel, information display, LLMS indicator, integrated overhead guard, armrest, top wiper, air conditioning assembly, seat, rear wiper, E-console, and window washer fluid reservoir.
Detailed removal and installation procedures are provided for various cab components, starting with the "Cab Door Assembly." To remove the cab door, technicians must open the sliding window, detach the gas spring, and open the door to a 90° angle. A caution advises using care when lifting the cab door to avoid damage to the cab frame. Lifting straps are to be attached through the sliding window opening, with a cushion placed between the window frame and straps to prevent damage. The door is then lifted out of its hinges and moved away from the lift truck. Installation involves reversing these steps, ensuring the door is properly seated on the hinges, moves correctly, and the locking system functions as intended. Adjustments to the hinges may be necessary.
The "Door Hinge" section details its removal and installation. After removing the cab door, the location of the hinges on the cab frame must be marked. The six capscrews retaining the hinges are removed, and the hinges are then detached. Installation involves positioning the hinges as marked, installing the capscrews loosely, installing the cab door, aligning the door lock with the striker pin, and then tightening the capscrews to a specified torque of 20 N·m (15 lbf ft).
The "Door Handle" removal involves removing a plastic plug from the inside of the door frame, followed by the capscrew and washer, and then the large nut and washer that retain the handle. The handle and two rubber cushions are then removed. Installation is the reverse, ensuring the locking system functions correctly.
For the "Door Latch," the door handle must first be removed. Then, the cap screws retaining the cover to the door latch are removed, followed by the nuts retaining the door latch to its housing. The door latch and bolts are then removed. Installation involves inserting the bolts, installing the door latch and nuts, installing the cap screw and washer for the cover, and finally installing the door handle, verifying the locking system's functionality.
The "Pedals" section covers the "Brake and Inching Pedal." Removal requires taking off the protection cover for the inch sensor and switch, disconnecting the rods under both pedals, removing the capscrews, washers, and nuts that retain the pedal assembly to the cab floor bracket, and then separating the inching pedal from the brake pedal, removing three shims and two bearings. Installation involves placing the bearings and shims correctly, positioning the pedal assembly, installing the retaining hardware, connecting the rods, and checking for necessary adjustments to the inching and brake pedals, referring to specific adjustment sections.
The "Accelerator Pedal and Sensor" removal involves disconnecting electrical connectors for throttle position and idle validation, and then removing three capscrews retaining the pedal to the cab floor. Installation is a matter of installing a new pedal and reconnecting the connectors.
The "SEAT ASSEMBLY" section provides instructions for removing and installing the seat, seat cushion, back cushion, and boot, as well as for replacing the seat suspension and suspension scissor and shock absorber. For seat removal, a lifting device is recommended. The battery ground cable must be disconnected, and electrical connectors for the seat (one for mechanical, two for air suspension) must be detached. The electrical plug at the instrument panel side console is also disconnected. The seat must be positioned fully forward or backward to access retaining capscrews. Four capscrews, washers, and nuts retaining the seat to the seat suspension are removed, and then the seat is lifted off. Installation reverses these steps, ensuring all electrical connections and the ground cable are reconnected.
"Seat Cushion" removal involves sliding the seat forward, adjusting the steering wheel upward, removing a screw and three clips from the cushion front, sliding the seat backward, and then lifting and rotating the cushion to detach it from the guide block and front. Further lifting detaches the rear. Cable ties and spade connectors securing the connector block to the cushion are cut and disconnected. Installation involves feeding cables, connecting spade connectors, attaching the connector block with a cable tie, locating and applying pressure to the rear tab, sliding the cushion until the tab is in place, applying a sharp blow to the front for a secure click, and installing new clips and a screw.
"Back Cushion" removal requires sliding the seat assembly forward, removing the headrest (if equipped), two guides, and two screws that retain the back cushion to the back pan. Installation is the reverse.
"Boot Replacement" involves removing the seat and then using a pry bar to remove 22 plastic plugs retaining the boot to the seat suspension. The old boot is removed, a new one installed, and the plastic plugs are reinserted.
"Seat Suspension Replacement" requires removing the seat and boot first. Then, four capscrews retaining the seat suspension to the cab floor are removed, and the suspension is lifted off. Installation is the reverse.
The "Suspension Scissor and Shock Absorber Replacement" section is extensive, with detailed steps for both air and mechanical seats, noting their similarities. It starts by removing the seat, seat suspension, and boot. The suspension is then positioned on a workbench with the lower housing facing upward. For air seats, retaining screws for the air bladder are removed. A 9/16" Allen wrench is used to remove the lower housing pivot shaft nut and then the pivot shaft itself. For mechanical seats, the lower housing is lifted, and the suspension scissor is placed in the highest raised position. The rear of the lower housing is lifted while sliding it forward to disengage height adjustment rollers from the roller channels. The rear of the lower housing is then rotated clockwise to disengage front suspension scissor rollers. The lower housing is removed from the suspension. For mechanical seats, tether belts are removed from the suspension scissor lower pivot tubes. The upper housing pivot shaft nut is removed with a 9/16" Allen wrench, followed by the pivot shaft. The weight indicator tension spring is removed from the suspension scissor. The suspension scissor is lifted and slid forward to disengage front suspension scissor rollers from the upper housing. Finally, the suspension scissor is removed from the upper housing, and for air seats, the bladder is removed. The tether belts are removed from the suspension scissor upper pivot tubes, followed by the rear bearing tubes and front suspension scissor rollers. The push-on PAL nut retaining the upper shock absorber bearing to the suspension scissor is also removed.
This manual is a comprehensive guide for maintaining and repairing the Hyster Operator's Cab, ensuring that technicians have the necessary information to perform their tasks safely and effectively, thereby contributing to the longevity and reliable operation of the lift truck.
General| Model | RS45-31CH |
|---|---|
| Power Source | Diesel |
| Travel Speed | 25 km/h |
| Fuel Type | Diesel |
| Load Center | 1, 200 mm |
| Load Capacity | 45, 000 kg (at 1200mm load centre) |
To Next Page