Twistlock indication is the most exacting system in this 220-page Hyster RS45-27CH operator manual PDF (OEM ID 4091122), covering seated and landed signal adjustment, twistlock angle and proximity switch setup on the 27CH and 31CH ReachStacker. Wider coverage starts with wiring diagrams that trace the power supply, start system, indicators, displays, transmission and hydraulic controls, plus hydraulic schematics of the circuit. Your daily walkaround covers the boom, rotator, spreader, air pre-cleaner and drive belt, while the lubrication chart and maintenance schedule reach boom wear pads, king pins, tie rods and transmission oil filter. Container pickup, deposit, trailer handling and twist lock override each get their own instructions. Real numbers follow. Hold brake accumulator pre-charge at 10.35 MPa and torque drive wheel nuts to 405 to 440 N·m. If you are tracing a hydraulic control or transmission circuit, the diagrams show how it connects. Bookmarked and text searchable, the file stays with you wherever the ReachStacker is working.
What's Inside This Hyster RS45-27CH, RS45-31CH Operator Manual
| System | Pages | Key Topics |
|---|---|---|
| Electrical System Components | 1 | Fuse Panel, Relays, Battery Disconnect Switch, Main Power Relay |
| Wiring Diagrams | 2-35 | Power Supply, Start System, Indicators, Displays, Transmission, Hydraulic Controls |
| Daily Inspections | 36-41 | Safety Labels, Boom, Rotator, Spreader, Air Pre-Cleaner, Drive Belt |
| Maintenance Schedule | 42-44 | Drive Axle, Differential Oil, Steer Wheel Hubs, Wheel Nuts, Hydraulic Tank Breather, Transmission Oil Filter |
| Lubrication Procedures | 45-49 | Boom Wear Pads, Boom Pivot, Drive Shaft, Tie Rods, King Pins, Steering Axle Pivot |
| Container Handling Instructions | 50-53 | Spreader Adjustment, Container Pickup, Container Deposit, Trailer Handling, Twist Lock Override |
| Maintenance Instructions | 54-62 | Lubrication Chart, Wear Pads, Twist Locks, Extension Cylinder, Spreader Extension Cylinders |
| Twistlock Indication and Adjustment | 63-85 | Seated Signal Adjustment, Landed Signal Adjustment, Twistlock Angle Adjustment, Proximity Switch, Sensor Bracket |
| Fuse Panel Layout | 86-117 | Engine Control Module, Transmission Control, Attachment Controls, Lighting Circuits, Climate Control, Power Outlets |
| Model Description | 118-187 | Seat Controls, LMI Slim Display Unit, Container Handler Control Box |
| Operating Procedures | 188-220 | Starting Procedures, Inching/Braking, Steering (Turning), How to Pick Up a Trailer |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Lubrisol 9990A Additives in hydraulic system oil | 3%-6% | p. 113 |
| Wheel Nuts Torque (Drive Wheel) | 405 to 440 N·m | p. 42 |
| Brake System Accumulator Pre-charge Pressure | 10.35 MPa | p. 43 |
| Engine Valve Lash (Inlet, Cold) | 0.36 mm | p. 43 |
| Engine Valve Lash (Exhaust, Cold) | 0.68 mm | p. 43 |
| Transmission Oil Capacity | 62 liter | p. 47 |
| Differential Oil Capacity | 40 liter | p. 47 |
| Hydraulic System Oil Capacity | 605 liter | p. 48 |
| Cooling System Fluid Capacity | 40 liter | p. 49 |
Hyster RS45-27CH, RS45-31CH Common Problems This Manual Covers
Hyster RS45-31CH instrument cluster hourmeter showing E or tE fault code on the fault code display
Check the code on the hourmeter/fault code display using page 89. A code starting with E is an engine fault; a code starting with t or tE is a transmission fault. Report it immediately and do not operate the lift truck until the problem is corrected. Put a DO NOT OPERATE tag in the operator's area and remove the key from the key switch, as page 74 directs.
Manual Section: Engine and Transmission Fault Codes p. 89LMI alarm code 24 or 25 for derricking cylinder pressure difference appearing during boom work
Apply the derricking up function and keep using the derricking functions. The LMI table on page 182 says the alarm normally clears within a few seconds. Code 24 is the piston side and code 25 is the rod side. If either code returns at high frequency, have the LMI system inspected. If code 33 shows, retract the boom to decrease the load moment.
Manual Section: LMI (Load Moment Indicator) Alarm Codes p. 182LMI alarm code 58, 59 or 60 showing with stabilizer not fully retracted
Retract the stabilizer completely before driving, following the corrective actions on page 183. Code 58 means the transmission is not in NEUTRAL, and code 59 means the park brake is not applied. For both, apply the park brake before extending the stabilizer; this also puts the transmission in NEUTRAL. For code 60, stop turning the steering wheel while the stabilizer is partially extended.
Manual Section: LMI (Load Moment Indicator) Alarm Codes p. 183Alternator warning light stays on with engine running and voltmeter needle out of green area
Check the alternator warning light against page 90. It should be ON with the key on and the engine stopped, and it should go OFF once the engine runs. The voltmeter needle should sit in the green area. Do not continue operating if the red light stays ON above idle. Tag the truck DO NOT OPERATE, remove the key, and report the repair as page 74 directs.
Manual Section: Electrical System p. 90Engine air filter electrical restriction indicator light coming on with the engine running
Replace the main element when the restriction indicator light is ON, per page 90. Change the safety element every third time the main element is replaced. Put a bright light inside the element to look for holes or damage. Clean the canister with a damp cloth and empty the dirt from the precleaner bowl. Dirt buildup in the housing can force the element in and crack it.
Manual Section: Engine Air Filter p. 90Transmission oil temperature warning light staying on or transmission not shifting smoothly during travel
Check the transmission oil hot, following page 93. Apply the parking brake, run the engine at idle, and put the shift lever in N (NEUTRAL). Use the dipstick on the right-hand side near the fuel filter and keep the level at the FULL mark. Do not run the engine with the gauge needle in the red area. If shifting stays rough, report it and do not operate the truck.
Manual Section: Transmission p. 93Frequently Asked Questions
What does alarm code 24 mean on a Hyster RS45-31CH?
Alarm code 24 indicates that there is too high of a pressure difference between the derricking cylinders at the piston side. You should continue using the derricking functions, as the alarm will normally go away within a few seconds after applying the derricking up function; if the alarm persists with high frequency, have the LMI system inspected. p. 182
What is the required torque for cab mounting bolts on the Hyster RS45-27CH, RS45-31CH?
The cab mounting bolts must be torqued to 66 N•m (49 lbf ft) during the initial 500-hour check. p. 41
What is the transmission oil capacity for the Hyster RS45?
The total capacity for the transmission oil is 62 liters (16 gallons). p. 39
What is the procedure for checking the engine oil level?
After the engine has stopped, wait one minute before checking the oil level. Maintain the oil at the Full mark on the dipstick when the engine is cold. p. 83
What is the required torque for drive wheel nuts on the Hyster RS45-27CH, RS45-31CH?
The wheel nuts for the drive wheels must be torqued to 405 to 440 N•m (299 to 325 lbf ft). p. 42
Is this Hyster RS45-27CH manual a download or a disc?
Immediate download of the complete 220-page searchable Operator Manual. Access it on any device, from a laptop at your desk to a phone in the field.
Am I able to print pages from this Hyster RS45-27CH manual?
You can. Print the sections you want for your own use and keep the file as your backup.
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