Hyster

OPERATING MANUAL
ReachStacker
RS45-27, 31 CH; RS46-36, 41L, 41S, 41LS CH;

RS45-24, 28 IH;RS46-33, 38L, 38S, 38LS IH;
(C222) SN E1609 => and also (C222) SN E1601
DO NOT REMOVE THIS MANUAL FROM THIS UNIT
PART NO. 4073819 2/14

Spacer
LIFT TRUCK MODEL SERIAL NUMBER
ENGINE MODEL SERIAL NUMBER
TRANSMISSION TYPE SERIAL NUMBER
MAST LIFT HEIGHT GROUP NUMBER
CARRIAGE TYPE GROUP NUMBER
DRIVE TIRE SIZE STEERING TIRE SIZE
SPECIAL EQUIPMENT OR ATTACHMENTS
© Hyster Company 2014. All rights reserved.
HYSTER, , FORTENS, and MONOTROL are Registered Trademarks of NACCO Materials Handling Group, Inc. DURAMATCH, UNISOURCE, AND
are Trademarks in the United States and certain other jurisdictions.
Foreword
Foreword
To OWNERS, USERS, and OPERATORS: and load handling operations before the new operator
attempts to operate the ReachStacker alone.
The safe and efficient operation of a ReachStacker
requires skill and alertness on the part of the operator. To It is the responsibility of the employer to make sure that the
develop the skill required, the operator must: operator can see, hear, and has the physical and mental
ability to operate the equipment safely.
• Receive training in the proper operation of this Reach-
Stacker. NOTE: A comprehensive operator training program is avail-
able from Hyster Company. For further details, contact your
• Understand any potential hazards that may exist in the dealer for HysterReachStackers.
work place where the ReachStacker is intended to be
used. This Operating Manual is the original instruction and con-
tains information necessary for the operation and mainte-
• Understand the capabilities and limitations of the Reach- nance of a basic ReachStacker. Optional equipment is
Stacker. sometimes installed that can change some operating char-
• Become familiar with the construction of the Reach- acteristics described in this manual. Make sure the neces-
Stacker and see that it is maintained. sary instructions are available and understood before
operating the ReachStacker.
• Read and properly understand the warnings, instructions,
and operating procedures in this manual. Some of the components and systems described in this
Operating Manual will NOT be installed on your unit. If you
In addition, a qualified person, experienced in ReachStacker have a question about any item described, contact your
operation, must guide a new operator through several driving dealer for Hyster ReachStackers.
©HYSTER COMPANY 2014 4073819 - ENGLISH-UK 1

Foreword
The following additional information is provided as specified — Declared whole-body vibration emission value is in
in Machinery Directive 2006/42/EC: accordance with EN 12096.
• Dimensional Details: Certain information is shown on the • Measured vibration emission value aW,Z = 0.3 m/s2
ReachStacker Nameplate. For additional dimensional
details on this or any other specific ReachStacker, consult • Uncertainty, K = 0,09 m/s2
your dealer. — Values determined according to EN 13059.
• Noise Levels: The measured Operators Ear Lpaz Value Hand-arm vibration:
is 76 dB(A) per EN 12053 for Stage IIIA engines.
The measured Operators Ear Lpaz Value is 73 dB(A) per — Hand-arm vibration emission value = <2.5 m/s2
EN 12053 for Stage IIIB engines. • Hazardous Atmosphere: Before any ReachStacker
• Human Vibration (Whole-Body and Hand-Arm Vibra- within the European Community can be operated in a
tion). Note: The whole-body vibration level is measured Potentially Explosive Atmosphere, it is necessary that the
according to standard EN 13059 which contains specific ReachStacker is suitably converted for the application.
test criteria (load, speed, roadway surface, etc.) Worksite Conversions should only be carried out by a Hyster
vibration levels may vary depending on actual operating approved supplier. Confirmation of the conversion can be
and surface conditions. made by referring to the ReachStacker Declaration of
Conformity which will confirm compliance with European
Whole-body vibration: Directive 94/9/CE. If you are in doubt, please contact your
Hyster dealer for assistance.
— Measured whole body vibration at the operator posi-
tion, based on standard production truck with full-sus- • Manufacturer: Hyster Europe, Centennial House, Build-
pension seat is listed below. ing 4.5, Frimley Business Park, Frimley, Surry GU16 7SG,
United Kingdom
2
Foreword
• The EC Conformity: Each lift truck ships with a unique
CAUTION
EC Declaration of Conformity certificate. See the end of
Indicates a hazardous situation which, if not avoided,
this section for a sample EC Declaration of Conformity
could result in minor or moderate injury and property
certificate which complies with Machinery Directive
damage.
2006/42/EC.
On the lift truck, the WARNING symbol is on orange
NOTE: Hyster ReachStackers are not intended for use on
background. The CAUTION symbol is on yellow back-
public roads.
ground.
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.
3
Foreword
Climatic Conditions
This range of ReachStackers is designed to work in normal climatic conditions. Normal climatic conditions are as follows:
Average ambient temperature for continuous duty: +45°C

Maximum ambient temperature, short term (up to 1 h): +40°C
Lowest ambient temperature for trucks intended for use in normal outdoor conditions: −20°C
Altitude: Up to 2000m
From 30% to 95%
Relative humidity:
(noncondensing)
4
Foreword
Lifting 1. Arrange for the modification or alteration to be designed,

tested, and implemented by an engineer(s) expert in
Lifting eyes and instruction decal are optional. DO industry trucks and their safety;
NOT lift a ReachStacker other than by jacks under 2. Maintain a permanent record of the design, test(s), and
the ReachStacker unless the lifting eye option or implementation of the modification or alteration;
special lifting eyes are installed. 3. Approve and make appropriate changes to the capacity
plate(s), decals, tags and instruction handbook;
Truck Modification 4. Affix a permanent and readily visible label to the truck
stating the manner in which the truck has been modified
Unauthorized truck modification is not permitted. To obtain or altered together with the date of modification or alter-
authorization contact your Hyster dealer. ation, and the name and address of the organization that
Only in the event that the truck manufacturer is no longer in accomplished the tasks.
business and there is no successor in the interest of the
business, the user may arrange for a modification or altera-
tion to a powered industrial truck, provided, however, that the
user shall:
5
Foreword
ReachStacker Specifications
Table 1. ReachStacker Specifications
Truck Length Engine Travel Speed Gradeability

Hyster Engine Engine Power
(with counter- Size (loaded/ (loaded/
Eur Model Model (kW)
weight) mm (L) unloaded) kph with 1.6 kph) %
RS45–27CH 8058 Cummins QSM 11 10.8 224 19.9/23.1 22
250 21.3/23.4 26
Cummins QSL 9 8.9 261 21.3/23.4 26
RS45–31CH 8058 Cummins QSM 11 10.8 224 19.9/23.1 22
250 21.3/23.4 26
Cummins QSL 9 8.9 261 21.3/23.4 26
RS46–36CH 8150 Cummins QSM 11 10.8 224 20.4/25.3 22
250 22.6/25.7 26
Cummins QSL 9 8.9 261 22.6/25.7 26
RS46-40CH 8350 Cummins QSM 11 10.8 224 18.7/22.4 19
250 20.4/23.9 22
Cummins QSL 9 8.9 261 20.4/23.9 22
6
Foreword
Table 1. ReachStacker Specifications (Continued)

RS46-41S CH 8450 Cummins QSM 11 10.8 224 18.7/22.4 19
250 20.4/23.9 22
Cummins QSL 9 8.9 261 20.4/23.9 22
RS46-41L CH 8950 Cummins QSM 11 10.8 224 18.7/22.3 19
250 20.4/23.8 22
Cummins QSL 9 8.9 261 20.4/23.8 22
RS46-41LS CH 9050 Cummins QSM 11 10.8 224 18.7/22.3 19
250 20.4/23.8 22
Cummins QSL 9 8.9 261 20.4/23.8 22
RS45–24IH 8058 Cummins QSM 11 10.8 224 19.9/23.1 22
250 21.3/23.4 26
Cummins QSL 9 8.9 261 21.3/23.4 26
7
Foreword

RS45–28IH 8058 Cummins QSM 11 10.8 224 19.9/23.1 22
250 21.3/23.4 26
Cummins QSL 9 8.9 261 21.3/23.4 26
RS46–33IH 8150 Cummins QSM 11 10.8 224 20.4/25.3 22
250 22.6/25.7 26
Cummins QSL 9 8.9 261 22.6/25.7 26
RS46-37IH 8350 Cummins QSM 11 10.8 224 18.6/22.3 19
250 20.3/23 22
Cummins QSL 9 8.9 261 20.3/23 22
RS46-38S IH 8450 Cummins QSM 11 10.8 224 18.6/22.3 19
250 20.3/23 22
Cummins QSL 9 8.9 261 20.3/23 22
8
Foreword

RS46-38L IH 8950 Cummins QSM 11 10.8 224 18.6/22.3 18
250 20.3/23 21
Cummins QSL 9 8.9 261 20.3/23 21
RS46-38LS IH 9050 Cummins QSM 11 10.8 224 18.6/22.3 18
250 20.3/23 21
Cummins QSL 9 8.9 261 20.3/23 21
9
10
Foreword
EC DECLARATION OF CONFORMITY
WE HYSTER EUROPE
CENTENNIAL HOUSE
BUILDING 4.5
FRIMLEY BUSINESS PARK
FRIMLEY, SURRY GU16 7SG
UNITED KINGDOM
DECLARE UNDER OUR SOLE RESPONSIBILITY THAT THE MACHINE
CATEGORY: FORKLIFT IC ENGINE POWERED
TYPE
SERIAL NUMBER(S)
YEAR OF CONSTRUCTION
IS IN CONFORMITY WITH THE MACHINERY DIRECTIVE 2006/42/EC. COMPLIANCE WITH

THIS DIRECTIVE IS ESTABLISHED BY MEETING THE TECHNICAL REQUIREMENTS OF THE
RELEVANT STANDARDS, INCLUDING EN ISO 3691-1
OTHER APPLICABLE DIRECTIVES:

2004/108/EC - EMC EMISSIONS
2000/14/EC - SOUND POWER FOR IC ENGINED FORKLIFT AS AMMENDED BY
2005/88/EC.
TYPICAL VALUE dB
GUARANTEED VALUE, dB
CONFORMITY ASSESSMENT PROCEDURE: INTERNAL CONTROL OF PRODUCTION AND
RESULTS OBTAINED BY FOLLOWING NMHG TEST PROCEDURE TEP 361, IN LINE WITH THE
REQUIREMENTS OF DIRECTIVE 2000/14/EC
TECHNICAL FILE CONTROLLED BY THE ENGINEERING MANAGER, NACCO MATERIALS
HANDLING LTD/B.V., CRAIGAVON, NORTHERN IRELAND/NIJMEGEN, THE NETHERLANDS.
NAME
POSITION PLANT MANAGER
(BLOCK LETTERS)
SIGNATURE
DATE
Contents
Contents
Foreword ..................................................................... 1 Know Your ReachStacker ........................................ 106
TO OWNERS, USERS, AND OPERATORS: ............. 1 Stability and Center of Gravity .................................. 107
CLIMATIC CONDITIONS ........................................... 4 Capacity (Weight and Load Center) ......................... 109
LIFTING ...................................................................... 5 LLMS (Longitudinal Load Moment Indicator) ........... 111
TRUCK MODIFICATION ............................................ 5 INSPECTION BEFORE OPERATION ........................ 112
REACHSTACKER SPECIFICATIONS ....................... 6 Checks With the Engine Stopped ............................. 112
Warning ....................................................................... 15 STARTING PROCEDURES ....................................... 113
Model Description ...................................................... 18 HEATING HYDRAULIC OIL ....................................... 114
GENERAL .................................................................. 20 EXHAUST SYSTEM REGENERATION (TIER 4I/
OPERATOR PROTECTION EQUIPMENT ................ 20 STAGE IIIB ENGINES ONLY) .................................. 114
NAMEPLATE .............................................................. 21 STATIONARY REGENERATION PROCEDURE ....... 115
SAFETY LABELS ....................................................... 21 MANUAL SHUTDOWN PROCEDURES .................... 115
CONTROLS, INSTRUMENTS, INDICATORS, AND DERATING AND AUTOMATIC SHUTDOWN
SWITCHES .............................................................. 25 PROCEDURES ........................................................ 115
LLMS (Longitudinal Load Moment Indicator) Indicator Coolant Temperature ............................................... 115
Lights .................................................................... 76 Intake Manifold Temperature ................................... 116
LLMS Check at Startup .......................................... 76 Engine Oil Temperature ........................................... 116
Green Indicator Light .............................................. 76 Engine Oil Pressure ................................................. 116
Red Indicator Light ................................................. 76 Empty Seat Engine Shutdown .................................. 116
Maximum Allowable Capacity ................................ 77 Operator Presence System (OPS) ........................... 116
Alarm Situation ....................................................... 77 NON-POWER SLIDING CAB SYSTEM ..................... 117
Amber Indicator Light ............................................. 77 POWERED SLIDING CAB SYSTEM ......................... 117
Operating Procedures ................................................ 106 AUTOMATIC GREASING SYSTEM (OPTIONAL) ..... 119
GENERAL .................................................................. 106 CHECKS WITH THE ENGINE RUNNING .................. 119
11
Contents
OPERATING TECHNIQUES ...................................... 120 DOCKS ....................................................................... 138
Basic Operating Procedures .................................... 121 ATTACHMENTS ......................................................... 138
Driving and Direction Changes ................................. 122 STOPPING ................................................................. 138
Inching/Braking ......................................................... 123 PARKING ................................................................... 139
Steering (Turning) .................................................... 124 Maintenance ................................................................ 140
Traveling ................................................................... 126 GENERAL .................................................................. 140
The Longitudinal Load Moment System (LLMS) ...... 128 Serial Number Data .................................................. 140
Stabilizer Operation .................................................. 128 HOW TO MOVE A DISABLED REACHSTACKER .... 141
Description ............................................................. 128 How to Tow the ReachStacker ................................. 141
Applying the Stabilizer ............................................ 129 HOW TO PUT A REACHSTACKER ON BLOCKS ..... 142
Returning to Drive Mode ........................................ 129 How to Raise the Drive Tires .................................... 142
Load Handling, How to Handle Containers .............. 130 How to Raise the Steer Tires ................................... 143
How to Pick Up a Container ................................... 130 HOW TO CLEAN A REACHSTACKER ...................... 145
Traveling with a Container or Trailer ...................... 132 Daily Inspections ........................................................ 146
How to Deposit a Container ................................... 132 Container Attachment Maintenance ......................... 169
Load Handling .......................................................... 133 Maintenance Procedures Every 8 Hours or
How to Pick up a Trailer ......................................... 134 Daily ............................................................................. 175
How to Deposit a Trailer ......................................... 134 HOW TO MAKE CHECKS WITH THE ENGINE
System overrides ...................................................... 135 STOPPED ................................................................ 175
LLMS override .......................................................... 135 Warning and Safety Labels ...................................... 175
Emergency lowering ................................................. 135 Wheels, Tires, and Tire Pressure ............................. 176
12 Degree Rotation override .................................... 136 Wheel Nuts ............................................................... 177
Lift Interrupt Function override ................................. 136 Boom, Rotator, and Spreader .................................. 177
Twist Lock Override .................................................. 136 Air Precleaner Dust Bowl ......................................... 177
Load Handling, Using a Sling ................................... 136 Hydraulic Tank Breathers ......................................... 178
12
Contents
Radiator Sections for Engine Coolant, Charge Air Transmission ............................................................ 195
Cooler, Transmission and Hydraulic Oil ............... 179 Operator Presence System ...................................... 195
Windshield Washer Fluid .......................................... 179 HOW TO ADD FUEL TO THE REACHSTACKER ..... 196
Hydraulic System Oil ................................................ 180 PNEUMATIC TIRES AND WHEELS .......................... 197
Engine Oil Level ....................................................... 182 Remove Wheels From the ReachStacker ................ 197
HOW TO MAKE CHECKS WITH ENGINE Remove Tire From the Wheel .................................. 199
RUNNING ................................................................. 185 Tire Removal From Five-Piece Wheel ................... 199
Seat Belt, Seat Rails, and Steering Column ............. 185 Install Tire on the Wheel ........................................... 200
Steering Column Latch ............................................. 186 Tire Installation on Five-Piece Wheel ..................... 201
Gauges, Lights, Horn, Fuses, and Relays ................ 186 Add Air Pressure to the Tires ................................... 202
Windows and Mirrors ................................................ 190 Install Wheels on the ReachStacker ........................ 203
Fault Codes .............................................................. 190 HOW TO PUT INTERNAL COMBUSTION ENGINE
High Exhaust System Temperature Light ................. 190 (ICE) REACHSTACKER IN STORAGE ................... 204
Engine Air Filter ........................................................ 190 Short-Term Storage .................................................. 205
Coolant Level ........................................................... 191 Long-Term Storage .................................................. 205
High Pressure Brake Cooling Filter .......................... 191 WHILE THE REACHSTACKER IS IN STORAGE ...... 206
Engine Oil Pressure ................................................. 193 HOW TO PUT BATTERIES IN STORAGE ................ 206
Fuel Level ................................................................. 193 PUTTING A STORED REACHSTACKER BACK INTO
Control Levers and Pedals ....................................... 193 SERVICE .................................................................. 207
Parking Brake ........................................................... 194 HOW TO MOVE A REACHSTACKER ON A
Service Brakes ......................................................... 194 TRANSPORT ........................................................... 207
Steering System ....................................................... 194 Loading ..................................................................... 208
Boom, Rotator, and Spreader Operation .................. 194 Unloading ................................................................. 209
Signals From the Spreader Control System ............. 195 PREPARATION AFTER TRANSPORT ...................... 209
Signals From the LLMS ............................................ 195
13
Contents
OPERATING PROCEDURES FOR A NEW OR Maintenance Register ................................................ 211
REBUILT ENGINE ................................................... 210
14
Warning
WARNING
FAILURE TO FOLLOW THESE INSTRUCTIONS CAN CAUSE SERIOUS INJURY OR DEATH!
AUTHORIZED, TRAINED OPERATOR ONLY!
KNOW THE EQUIPMENT: LOOK WHERE YOU ARE GOING:

• ALWAYS use 3 points of contact when getting on and off • IF YOU CAN'T SEE, DON'T GO.
the ReachStacker.
• TRAVEL in reverse if load blocks forward vision.
• KNOW operating, inspection, and maintenance instruc-
• MAKE SURE tail swing area is clear.
tions in Operating Manual.
• SOUND horn at intersections or where vision is blocked.
• DO NOT operate or repair the ReachStacker unless
trained and authorized. • WATCH clearances, especially overhead.
• INSPECT ReachStacker before use. KNOW YOUR LOADS:
• DO NOT operate if ReachStacker needs repair. Tag • HANDLE only stable loads within specified weight and
ReachStacker and remove key. Repair ReachStacker load center. See Nameplate on ReachStacker.
before use. Always use Hyster Approved parts when
USE COMMON SENSE:
making repairs. Replacement parts must meet or exceed
the specifications of the original equipment manufacturer. • DO NOT use ReachStacker to lift people unless there is
no other practical option. Then, use only a securely
• USE auxiliary equipment (attachments) for intended pur-
attached special work platform. Follow instructions in this
pose only.
Operating Manual.
• OBEY traffic rules. Yield right-of-way to pedestrians.
15
Warning
WARNING
• BE in complete control at all times. • DO NOT start if fuel is leaking.

• ALLOW NO ONE under or near lift mechanism or load. • KEEP vent caps clear when charging battery.
• OPERATE ReachStacker only from operator's seat. • DISCONNECT battery during servicing.
• KEEP arms, legs, and head inside operator's compart- • CHECK dockboard width, capacity, and security.
ment.
PROTECT YOURSELF FASTEN YOUR SEAT BELT!
• DO NOT move ReachStacker if anyone is between
• AVOID bumps, holes, and loose materials.
ReachStacker and stationary object.
• AVOID sudden starts or stops.
• BEFORE PARKING, neutralize shift lever, lower , and set
brake. • NEVER turn on or angle across an incline.
• WHEN PARKING, also shut off power and block wheels • TRAVEL on inclines with load uphill or when unloaded
on inclines. with lift mechanism downhill.
KNOW THE AREA: • TRAVEL forward with the load or carriage approximately
1 m (3.3 ft) above seat.
• FILL fuel tank or charge battery only in designated area.
• SLOW DOWN before turning, especially without load.
• TURN OFF engine when fueling.
• AVOID sparks or open flame. Provide ventilation.
16
Warning
WARNING
FAILURE TO FOLLOW THESE INSTRUCTIONS CAN

CAUSE THE ReachStacker TO TIP.
DO NOT JUMP off if the ReachStacker tips over. HOLD
steering wheel firmly. BRACE your feet. LEAN FOR-
WARD and AWAY from point of impact.
17
Model Description
Model Description
Figure 1. Model View Showing Major Components
18
Model Description
Legend for Figure 1
1. ATTACHMENT 5. STEERING AXLE
2. BOOM 6. FUEL TANK
3. OPERATOR COMPARTMENT/CAB 7. DRIVE AXLE
4. COUNTERWEIGHT 8. STABILIZER (IF EQUIPPED)
19
Model Description
Model Description
General The ReachStacker can be equipped with a stabilizer function
in combination with the standard frame or extended frame.
This Operating Manual is for ReachStacker with serial num-
ber E1601 and higher, including E1601, and covers the fol- The ReachStacker can also be equipped with tie points for
lowing models: ropes or chains to be used with a sling. If ReachStacker is
used in conjunction with a sling, load swing must be limited.
RS45-27CH Secure load to the ReachStacker frame with ropes or chains.
RS45-31CH
RS46-36CH These ReachStackers have either a Cummins QSM11 or
RS46-41L CH QSC9 diesel engine and TE27/32 Powershift™ transmission
RS46-41S CH with four speeds FORWARD and four speeds REVERSE.
RS46-41LS CH A shift lever is on the left side of the steering column. It con-
RS45-24IH trols the FORWARD, NEUTRAL, and REVERSE operation
RS45-28IH as well as the four transmission speed ranges. An acceler-
RS46-33IH ator pedal controls the speed of the engine.
RS46-38L IH
RS46-38S IH Operator Protection Equipment
RS46-38LS IH
The operator compartment is intended to offer reasonable
The ReachStacker can be equipped with a spreader for con- protection to the operator from falling objects, but cannot
tainer handling only (CH model) or it can have an intermodal protect against every possible falling object. Therefore, it
spreader (IH model) for containers and trailers. All spreaders must NOT be considered a substitute for good judgment and
can handle from 20- to 40-ft containers. See Figure 1. care when handling loads. See Figure 1.
20
Model Description
The seat belt provides an additional method to help the oper- ReachStacker nameplate does not show the capacity chart
ator keep the head and body substantially within the confines reference number, or if the ReachStacker equipment does
of the lift truck frame and operator compartment if a tipover NOT match that shown on the nameplate, the ReachStacker
occurs. This restraint system is intended to reduce the risk must NOT be operated, until the correct rated capacity is
of the head and body being trapped between the Reach- known.
Stacker and the ground, but it cannot protect the operator
When a ReachStacker is shipped incomplete from the fac-
against all possible injury in a tipover. Always fasten the seat
tory, the nameplate is covered by an INCOMPLETE label as
belt.
shown in Figure 2. If the equipment on the ReachStacker is
Nameplate changed, the nameplate is covered by a NOTICE label as
shown in Figure 2. If your ReachStacker has either of these
WARNING labels, DO NOT operate the ReachStacker. Contact your
DO NOT add to or modify the ReachStacker. Any change dealer for Hyster ReachStacker to obtain a complete correct
to the ReachStacker, the tires, or its equipment can nameplate.
change the lifting capacity. The ReachStacker must be Safety Labels
rated as equipped and the nameplate must show the
correct capacity rating or personal injury may occur. Safety labels are installed on the ReachStacker to give infor-
mation about possible hazards. It is important that all safety
The capacity for the ReachStacker, as it is equipped, must
labels are installed on the ReachStacker and can be read.
be shown on the nameplate. The nameplate refers to a
See Figure 3. If labels that have warnings or cautions are
capacity chart that is fitted above the nameplate. The chart
damaged, they must be replaced. Refer to the Parts Man-
reference number on the nameplate must be identical to the
ual for the labels and the location of the labels.
number shown at the bottom of the capacity chart. If the
21
Model Description
A. NAMEPLATE B. NOTICE LABEL C. INCOMPLETE LABEL D. SAMPLE CAPACITY CHART
Figure 2. Nameplate and Label
22
Model Description
SEE THE PARTS MANUAL FOR LABEL PART NUMBER AND LOCATION.
Figure 3. Warning and Safety Labels
23
Model Description
Legend for Figure 3
1. OPERATION WARNING LABEL 8. REPLACE OPERATING MANUAL LABEL
2. MAST WARNING LABEL 9. BATTERY DISCONNECT LABEL
3. NAMEPLATE 10. OPERATOR RESTRAINT LABEL
4. NO RIDERS WARNING LABEL 11. CONTROL BOX WARNING LABEL
5. FAN WARNING LABEL 12. PARK BRAKE WARNING LABEL
6. DOOR RELEASE WARNING LABEL 13. OVERHANG BOOM WARNING LABEL
7. ETHER WARNING LABEL 14. PINCH POINT WARNING LABEL
24
Model Description
Controls, Instruments, Indicators, and

Switches
A. AIR SEAT B. MECHANICAL SEAT
Figure 4. Seat Controls
25
Model Description
Table 2. Seat Controls (See Figure 4)
Item Item Function

No.
1 Seat Belt and Seat Belt Retractor Seat belt must be properly fastened before starting lift truck operations.
2 Arm Rest Adjustment Controls the angle of the armrest.
3 Back Rest Adjustment Controls the vertical angle of the backrest.
LIFT the lever to release and adjust the backrest.
PUSH down the lever to lock the backrest in position.
4 Air Seat Height Adjustment Controls the height of the seat.
PUSH the knob to raise seat.
PULL the knob to lower seat.
5 Air Seat Weight Adjustment TURN knob clockwise to achieve a smoother suspension.
TURN knob counterclockwise to increase rigidity of the suspension.
6 Forward/Backward Controls the FORWARD and BACKWARD movement of the seat on the seat
Seat Movement rails.
LIFT lever to release the seat for adjustment.
PUSH lever down to lock the seat in position.
26
Model Description
Table 2. Seat Controls (See Figure 4) (Continued)
Item Item Function

No.
7 Mechanical Seat Controls the height of the mechanical seat. Rotate this knob to raise or lower the
Height Adjustment height of the seat.
27
Model Description
Figure 5. Sears Deluxe Seat
28
Model Description
Table 3. Seat Controls (See Figure 5)
Item Item Function

No.
1 Seat Belt and Seat Belt Retractor Seat belt must be properly fastened before starting lift truck operations.
2 Lumbar Adjustment Push top of switch to increase lumbar support.
Push bottom of switch to decrease lumbar support.
3 Seat Heating Switch Push top of switch to switch heating ON.
Push bottom of switch to switch heating OFF.
4 Height/Weight Adjustment Sit in the seat and push top of switch for automatic adjustment into mid height
and mid stroke position.
To change the height for individual needs, push top of switch to raise and push
bottom of switch to lower the seat.
5 Armrest Tilt Adjustment Turn the knob to adjust the tilt angle of the armrest.
6 Back Rest Adjustment Lift the lever to release and adjust the backrest.
Push down on the lever to lock the backrest in position.
7 Fore/Aft Isolator Lift lever to allow 25 mm (1 in.) fore/aft movement.
Press lever down to lock fore/aft movement.
29
Model Description
Item Item Function

No.
8 Swivel Adjustment Seat can be swiveled into three 7° increments to the right and left.
Lift lever and swivel seat into desired position.
Release the lever to lock.
9 Damper Adjustment Turn knob clockwise to increase rigidity of the suspension.
Turn knob counterclockwise to achieve a smoother suspension.
10 Fore/Aft Seat Assembly The lever controls the 200 mm (7.8 in.) forward and backward position adjust-
Adjustment ment of the seat assembly in 10 mm (0.3 in.) increments.
Lift the lever to release the seat for adjustment.
Push lever down to lock the seat in position.
11 Fore/Aft Cushion Adjustment The lever controls the 60 mm (2.3 in.) forward and backward position adjustment
of the cushion in 10 mm (0.3 in.) increments.
Lift the lever to release the cushion for adjustment.
Push lever down to lock the cushion in position.
30
Model Description
Item Item Function

No.
12 Seat Cushion Tilt Adjustment The lever controls the tilt position of the cushion in two increments of 5 degrees.
Lift the lever to release the cushion for adjustment.
Push lever down to lock the cushion in position.
31
Model Description
Figure 6. Spring-Assisted Armrest
32
Model Description
Table 4. Spring-Assisted Armrest (See Figure 6)
Item No. Item Function

1 Lever PULL AND HOLD lever to unlock spring-assisted armrest.
PUSH OR PULL armrest until it has reached the desired position.
RELEASE lever to lock spring-assisted armrest.
2 Front/Rear Adjustment TURN counterclockwise to allow adjustment.
TURN clockwise firmly to secure in desired position.
3 Sideways Adjustment TURN counterclockwise to allow adjustment.
TURN clockwise firmly to secure in desired position.
33
Model Description
Figure 7. Instrument and Indicators (Sheet 1 of 2)
34
Model Description
Figure 7. Instrument and Indicators (Sheet 2 of 2)
35
Model Description
Table 5. Instruments and Indicators (See Figure 7)
Item
Item Function
No.
1 Central Warning
WARNING
Lights
When these red lights are ON, there is a fault condition with the lift truck.
Stop the truck and look at instrument panel to determine which system
has a fault condition or lift truck damage or personal injury may occur.
2 Coolant Gauge indicates coolant temperature when the key switch is in the ON position.
Temperature When the temperature is near a critical value, the gauge symbol will FLASH
Gauge red and the engine warning light and the central warning lights will come ON.
A fault code will be displayed. Engine performance may decrease. When the
temperature has exceeded a critical value, the engine stop light will be ON and
the buzzer will sound. Immediately shut down the engine, or damage to the
lift truck will occur.
NOTE: For emergency situations, automatic engine shutdown can be reset.
Turn the key switch to OFF, and then to ON position, and restart the engine.
If the fault is still present, the engine will only run for a limited time.
36
Model Description
Table 5. Instruments and Indicators (See Figure 7) (Continued)
Item
Item Function
No.
3 Hourmeter/Fault The hourmeter operates while the engine is running. Periodic maintenance
Code Display recommendations are based on these hours. It also displays engine, trans-
mission, and hydraulic faults. Additional information is indicated when faults
occur. If more than one fault is present, the faults will scroll.
The explanation of fault codes is located in Table 6 and Table 7.
4 Engine Warning This warning light is ON when an engine fault has been detected. The central
Light warning lights will be ON. Determine which fault is present and take appropriate
action immediately.
5 Engine Stop If the red engine stop warning light comes ON, there is a critical fault condition.
Warning Light A fault code will be displayed. The buzzer will sound. The central warning lights
will be ON. Immediately shut down the engine, or damage to the lift truck
will occur.
NOTE: For emergency situations automatic engine shutdown can be reset.
Turn the key switch to OFF and then to ON, and restart the engine. If the fault
is still present, the engine will only run for a limited time.
37
Model Description
Item
Item Function
No.
6 Transmission This warning light is ON when a transmission fault has been detected. The
Warning Light central warning lights will be ON. A fault code will be displayed. Determine
which fault is present and take appropriate action immediately.
7 Transmission Red light will FLASH if a incorrect pressure is detected. A fault code will be
Pressure Feedback displayed. The transmission may shift to NEUTRAL. The buzzer will sound.
Warning Light The central warning lights will come ON. Shutdown mode remains selected
until the controller is switched OFF.
8 Transmission Oil This gauge indicates transmission oil temperature when the key switch is in
Temperature the ON position. When the temperature is near a critical value, the gauge sym-
Gauge bol will FLASH red, the transmission warning light and the central warning
lights will be ON. A fault code will be displayed. Engine performance may
decrease. When the temperature has exceeded a critical value, the buzzer will
sound. Immediately shut down the engine, or lift truck damage will
occur.
38
Model Description
Item
Item Function
No.
9 Transmission This orange light is ON when the transmission calibration switch in the side
Calibration console has been activated and is in the down position. For normal truck oper-
Warning Light ation the transmission calibration switch must be deactivated (in the up posi-
tion) and the transmission calibration warning light must be OFF.
10 Hydraulic System This orange warning light is ON when an hydraulic system malfunction has
Malfunction been detected. The central warning lights will be ON.
Warning Light
A fault code will be displayed. Determine which fault is present and take appro-
priate action immediately.
11 Hydraulic Oil This light is not functional and remains OFF during operation. This light is
Filter Restriction ON during the initial light check only.
Warning Light
(Optional)
39
Model Description
Item
Item Function
No.
12 Hydraulic Oil High
CAUTION
Temperature Warning
Do not continue to operate the lift truck when the red light is ON, or lift
Light (Optional)
truck damage may occur.
Red warning light comes ON when the hydraulic oil temperature is high. The
buzzer sounds. The central warning lights will be ON. For QSM 11 engines,
engine performance may decrease. When engine oil pressure is below a crit-
ical value, the engine stop light will be ON and the buzzer will sound. Shut
down the engine immediately, or damage to the lift truck will occur.
13 Brake System
WARNING
Low Pressure
Do not operate the lift truck when the red light is ON. Immediately shut
Warning Light
down the engine, or personal injury may occur.
Red warning light comes ON when the brake pressure is low. The buzzer will
sound. The central warning lights will be ON.
After starting the engine, wait until the light is OFF, before releasing the park
brake or operating the lift truck.
40
Model Description
Item
Item Function
No.
14 Parking Brake Red warning light is ON when the parking brake is applied.
Warning Light
15 Voltmeter Gauge The voltmeter indicates the system voltage. When the ignition is ON and the
engine is not running, the gauge symbol will be red. When the engine is running
and the system voltage is below 22.5 VDC, the gauge symbol will FLASH red.
The central warning lights will be ON.
16 Fuel Level Gauge When the fuel level is 10% or less of the tank capacity, the gauge symbol will
FLASH red. The central warning lights will be ON.
41
Model Description
Item
Item Function
No.
17 Engine When the engine is running, the needle is approximately in the middle of the
Oil Pressure gauge, indicating normal engine oil pressure. When engine oil pressure is near
Gauge a critical value, the gauge symbol will FLASH red, the engine warning light and
the central warning lights will come ON, and a fault code will be displayed.
Engine performance may decrease. When engine oil pressure is below a crit-
ical value, the engine stop light will be ON and the buzzer will sound. Imme-
diately shut down the engine, or damage to the lift truck will occur.
NOTE: For emergency situations automatic engine shut down can be reset.
Turn the key switch to OFF, and then to ON position, and restart the engine.
If the fault is still present, the engine will only run for a limited time.
18 Seat Belt
WARNING
Warning Light
Before driving the lift truck, always fasten your safety belt or personal
injury may occur.
Orange light is ON for 10 seconds after the key is placed in the ON position.
42
Model Description
Item
Item Function
No.
19 High Exhaust This warning light is ON when the regeneration process for the diesel partic-
Temperature ulate filter has caused that the temperature of the exhaust system has excee-
Warning Light ded a certain level. Make sure the exhaust pipe outlet is not directed at any
(Tier 4i/Stage IIIB surface or material that may become hazardous.
Engines Only)
If the area does not allow high exhaust system temperatures, switch the
Regeneration Control Switch to the ON position to postpone regeneration of
the diesel particulate filter. Perform a Stationary Regeneration Procedure at
earliest convenience. See Exhaust System Regeneration (Tier 4i/Stage IIIB
Engines Only).
20 Regeneration Inhibit This warning light is ON when the switch on the top of the Regeneration Control
Warning Light System has been flipped to the ON position. Switch the regeneration inhibit
(Tier 4i/Stage IIIB switch to OFF as soon as the truck is in an environment that allows high
Engines Only) exhaust system temperatures.
43
Model Description
Item
Item Function
No.
21 Diesel Particulate This warning light is ON when regeneration of the diesel particulate filter is
Filter Light required. This warning light flashes when regeneration of the diesel particulate
(Tier 4i/Stage IIIB filter has become urgent. Move the truck at earliest convenience to an area
Engines Only) that allows high exhaust system temperatures and perform a Stationary
Regeneration Procedure.
For a description of the stationary regeneration procedure, see Exhaust Sys-
tem Regeneration (Tier 4i/Stage IIIB Engines Only).
22 Engine Air Filter Orange engine air filter warning light is ON when the air filter is dirty or has an
Warning Light obstruction. If the light is ON, replace the main filter element. The central warn-
ing lights will be ON.
23 Engine Wait to This warning light is ON for 15 seconds after the key is turned to the ON position
Start Light when engine temperature is below −3 °C (27 °F). It indicates that the cold start
aid has been activated. After 15 seconds, the light will go OFF to indicate that
the engine can be started.
44
Model Description
Table 6. Explanation of Fault Codes
Code Starts With System Reference or Explanation

E Engine See Engine Fault Code Guide 600 SRM 1101.
t Transmission See APC200 Fault Code Guide 1300 SRM 1435.
tE Transmission See Table 7.
h Hydraulics See Hydraulic Control System 1900 SRM 1534.
hCold Hydraulics Hydraulic oil temperature in the reservoir is below −5 °C (23 °F). All hydraulic
functions can be operated normally, but the controller limits engine speed pro-
portional to the hydraulic oil temperature. At −20 °C (−4 °F), the engine speed is
limited to 1000 rpm. Above −5 °C (23 °F), the controller does not limit engine
speed. Limitation of the engine speed reduces maximum hydraulic performance.
Apply hydraulic functions to raise hydraulic oil temperatures.
hHot Hydraulics Hydraulic oil temperature in the reservoir exceeds 90 °C (194 °F). Reduce
hydraulic oil temperature by reducing hydraulic power demand until code hHot
has disappeared.
bHot Brakes Hydraulic oil temperature at the brakes exceeds 110 °C (230 °F). Reduce
hydraulic oil temperature by reducing usage of the brakes eg by limiting travel
speed.
fUel Engine Fuel level is 10% or less of tank capacity. Refuel soon.
45
Model Description
Table 7. Transmission Exceed Codes
Code Explanation Operator Action

tE001 The vehicle speed is too high to make the requested Slow down the vehicle to allow the controller to down-
downshift. shift.
tE101 The vehicle speed is too high to make the requested Be aware that the controller has put the transmission
direction change. into neutral. Slow down the vehicle to allow the control-
ler to change direction.
tE201 The engine speed is too high to make the requested Lower engine speed.
direction change or re-engagement..
tE300 The reduced vehicle speed limitation is active. Be aware.
tE301 The reduced vehicle speed limitation is active, however, Reduce vehicle speed below the maximum vehicle
the vehicle speed is above the speed limitation. speed.
tE302 The vehicle speed is above the maximum vehicle speed Reduce vehicle speed below the maximum vehicle
limit. speed.
tE400 Abnormal acceleration is detected. One or both drive wheels are skidding. Automatic shift-
ing is disabled. Adjust braking effort to floor conditions.
tE401 Abnormal acceleration is detected. One or both drive wheels are spinning. Automatic shift-
ing is disabled. Apply throttle according driving condi-
tions.
tE501 Transmission needs recalibration. Contact Maintenance to have the transmission recali-
brated.
46
Model Description
Table 7. Transmission Exceed Codes (Continued)
Code Explanation Operator Action

tE600 Operator is not seated and shift lever is NOT in Neutral Shift lever to neutral and/or apply parking brake.
and/or parking brake is NOT activated.
tE701 Turbine speed exceeds the limit. Reduce vehicle speed. The controller has reduced
engine speed to idle.
47
Model Description
Table 8. Climate Control Operating Instructions
Controls 1. LCD Display

During normal operation, the set-point temperature, blower speed,
operation mode and fresh/recirc air selection are displayed. In
Test/Diagnostic mode, error messages will be displayed on screen
for troubleshooting. Display's contrast is automatically compensa-
ted for all temperatures.
2. SET/SELECT Button
During normal operation, it is used for selecting between modes.
In Test/Diagnostic mode, it is used to test and diagnose different
components with the HVAC system.
3. Power Button
Turns HVAC unit ON and OFF.
Main Display Screen 1. Air Circulation Setting
The air mix can be set from full fresh air or full recirculated air.
2. Mode
It displays HVAC system's modes (Automatic, Heat, Cool, and
Defrost).
3. Temperature Set-Point
Displays current inside set-point temperature.
4. Blower Speed
Displays current blower speed setting.
48
Model Description
Table 8. Climate Control Operating Instructions (Continued)
Operation Menus
Main Screen:
When the controller is turned on, the main screen will appear. Current
set-point temperature, climate control mode, air-circulation and blower
speed are displayed. A symbol will be displayed when there is any

fault with the HVAC system.
Blower Speed Settings:

Press the SET knob until the blower icon appears, then turn the knob
clockwise to increase blower speed and counterclockwise to decrease
blower speed with 5% increments. Blower speed cannot be adjusted
in defrost mode.
49
Model Description
Climate Control Mode Settings:

Press the SET knob until the climate control mode icon appears, then rotate the
SET knob until required control mode is displayed.
AUTO: According to the temperature set-point, the controller takes
over and constantly analyzes system's electronic temperature sensors
to maintain temperature.
Cool: Cycling of the A/C compressor controls interior temperature. The
heater valve will remain closed,
Heat: Interior temperature is regulated with the electronic heater valve.
A/C compressor will remain off when heat mode is activated.
Defrost: When defrost mode is activated, the A/C compressor is turned
on, blower is turned on full speed and heater valve is fully opened.
Air Circulation Settings:
Press the SET knob until the air circulation mode icon appears. Turn
the knob clockwise for full recirculated air or counterclockwise for full
fresh air.
50
Model Description
Display Settings:
To adjust display settings and temperature scale, press the SET knob
until the display settings screen appear. Then, turn SET knob clockwise
or counterclockwise to adjust settings.
Turning HVAC System OFF:

In the main screen, press the Power button to switch of HVAC system
off. When system is turned off, the back light will switch off and the cab
interior temperature will be displayed on screen.
51
Model Description
Figure 8. Switches on Side Console
52
Model Description
Table 9. Switches (See Figure 8)
Item Item Function

No.
1 Key Switch The key switch has three positions:
No. 1 Position: OFF. De-energizes all electric circuits except for the horn and
headlights.
No. 2 Position: ON. Energizes all electric circuits except the starter circuit.
The key switch will be in this position during normal operation.
No. 3 Position: START. Energizes the starter motor for starting the engine. A
spring returns the key to position No. 2, (ON), when the key is released.
NOTE: There is a mechanical lockout that prevents the key switch from being
returned to the START position without first being returned to the OFF posi-
tion.
2 Optional Auxiliary 12 VDC 12 VDC Max 10 Amps outlet.
Power Outlet
53
Model Description
Table 9. Switches (See Figure 8) (Continued)
Item Item Function

No.
3 Heater/Air Conditioner Switch controls the fan for the heater, defroster, and A/C systems.
Fan Switch
Turn the switch to the right to increase the speed of the fan.
4 Heat Control Knob Knob controls the heater valve.

To close the heater valve, turn knob counterclockwise.
When knob is turned to the left, cab heat decreases.
When knob is turned to the right, cab heat increases.
5 Air Control Knob Knob controls fresh air ventilation in the cab through the cab vents.
When knob is turned to the left, fresh air enters the cab.
When knob is turned to the right, air is recirculated in the cab.
54
Model Description
Item Item Function

No.
6 Optional A/C Switch Switch controls the operation of the air conditioning (A/C) system.
PUSH top of switch to turn the A/C system ON.
NOTE: When A/C is switched ON, set the cabin heating control to the cold
position.
7 Parking Brake
WARNING
Knob
Apply parking brake before leaving ReachStacker. Parking brake is NOT
automatically applied. Always apply brake when leaving truck or Reach-
Stacker damage or personal injury may occur.
The round, red knob controls the operation of the parking brake as follows:
• With the knob PUSHED in, the parking brake is released.
• When the knob is PULLED out, the parking brake is applied.
NOTE: Before applying the park brake, make sure that the ReachStacker has
come to a complete stop.
NOTE: The parking brake must be applied before starting the engine.
55
Model Description
Item Item Function

No.
8 Attachment Work Light Switch controls lights for the container attachment.
PUSH on top of switch to turn lights ON.
Push bottom of switch to turn lights OFF.
9 Front Fender This switch controls the side, tail, and front fender lights.
Lights Switch
PUSH switch to first position to switch side and tail lights ON.
PUSH switch to second position to additionally switch the front fender lights
ON.
PUSH bottom of switch to turn lights OFF.
10 Work Lights This switch can either be a one position switch or a two position switch.
Switch
PUSH top of switch to move the switch from OFF to position 1 and 2.
PUSH bottom of switch to return the switch from position 2 to position 1 and
OFF.
As a one position switch it either switches the rear working lights ON, or the
boom, side and tail lights. As a two position switch the boom, side and tail
lights are ON in position 1. In position 2 the optional rear working lights are
also ON.
56
Model Description
Item Item Function

No.
11 Beacon Switch Switch controls the beacon.
PUSH the switch to turn the beacon ON.
12 Hazard Switch This switch controls the hazard warning lights.
PUSH on the switch to turn lights ON.
57
Model Description
Item Item Function

No.
13 Regeneration Control Switch, This switch has three positions. Normally, this switch is in the neutral position.
Tier4i/Stage IIIB only
Push top of switch to inhibit regeneration of the diesel particulate filter. The
Regeneration Inhibit Warning Light will be ON.
Push bottom of switch to the neutral position to allow regeneration of the die-
sel particulate filter. The Regeneration Inhibit Warning Light will be OFF.
Push bottom of switch against spring force to initiate the Stationary Regen-
eration Procedure. Release the button to allow the switch to return to the
neutral position.
The Stationary Regeneration Procedure will start only if the bottom of the
switch is pushed while the Diesel Particulate Filter Light is ON or while
FLASHING.
See also Exhaust System Regeneration (Tier 4i/Stage IIIB Engines
Only).
14 Diagnostic Switch This switch is used to access and exit the fault log mode. The procedure to
access and exit is described in the SRMs listed in Table 6.
15 Top Window Heating Switch This switch controls the electrical heating of the window. PUSH top of switch
(Optional) to turn heating ON. PUSH bottom of switch to turn heating OFF.
58
Model Description
Item Item Function

No.
16 Load above Cab Warning Light The amber warning light is ON when the load is above the cab. The sliding
cab can not be moved forward and the boom can not be retracted as long as
the load is above the cab.
17 Powered Sliding Cab
WARNING
Override Button
Use caution when sliding the cab with the doors open or personal injury
may occur.
When the button is pushed the cab can slide forward or backward despite the
door(s) being open. Normally the door(s) must be closed to move the cab.
18 Attachment Rotation Override Button Push this button and operate the rotating function on the joystick to rotate the
attachment beyond the 12° rotation limit
19 Button (Optional) Not Used
59
Model Description
Item Item Function

No.
20 Set/Select Button This button is used to select and set the different climate modes. See Oper-
(Optional) ating Instructions.
60
Model Description
Item Item Function

No.
21 Power ON/OFF Button Push the button to switch the electronic climate control unit ON and OFF.
(Optional)
Battery Disconnect Battery disconnect lever is located on the right hand side of lift truck in the
Lever battery box. Operation of lever is shown on the label.
NOTE: DO NOT operate battery disconnect lever until 60 seconds after key
switch is in OFF position.
61
Model Description
Figure 9. Controls and Signals
62
Model Description
Table 10. Controls and Signals (See Figure 9)
Item Item Function

No.
1 Shift Lever The travel directions are controlled by the shift lever.
PUSH the shift lever to move to FORWARD (F) to travel in the forward posi-
tion.
PULL the shift lever to move to REVERSE (R) to travel in the reverse position.
Center position is NEUTRAL (N).
Place the shift lever in NEUTRAL (N) position or depress inching/brake pedal
if shift lever is in FORWARD (F) or REVERSE (R) position before the engine
can be started.
Transmission shift lever has four range positions:
1 - First gear. Transmission will stay in this gear until operator selects another
gear.
2 - Second gear. Transmission will stay in this gear until operator selects
another gear.
63
Model Description
Table 10. Controls and Signals (See Figure 9) (Continued)
Item Item Function

No.
1 Shift Lever 3 - Third position will allow the transmission to automatically shift between
(cont) second and third gears depending on speed.
4 - Fourth position allows transmission to automatically shift between second,
third, and fourth gear depending on speed.
NOTE: All four speeds are available in the FORWARD and REVERSE direc-
tion of travel as selected by the operator.
NOTE: The transmission will automatically shift to NEUTRAL (N) if the trans-
mission oil pressure is low or if the oil is too hot. This will occur with the lever
in any position. To override the transmission protection in case of emergency,
turn the key switch OFF and then ON and restart the engine. This will allow
lift truck movement in first gear for 30 seconds.
64
Model Description
Item Item Function

No.
2 Steering Column
WARNING
Adjustment
Make sure steering column adjustment lever is locked into place before
moving ReachStacker. Never attempt to adjust steering column when
ReachStacker is moving or personal injury may occur.
Steering column tilts FORWARD, BACKWARD, and TELESCOPES for
adjustment. Release lever and move steering column to desired position, then
fasten lever.
3 Steering Wheel Steering wheel controls position of steer tires.
65
Model Description
Item Item Function

No.
4 Central Warning
WARNING
Lights
When these red lights are ON, there is a fault condition with the Reach-
Stacker. Stop the truck and look at instrument panel to determine which
system has a fault condition or ReachStacker damage or personal injury
may occur.
5 Horn Horn button controls operation of the horn.
6 Cab Vent Cab vent provides fresh air to the operator's cab from the heater or air con-
ditioning units.
66
Model Description
Item Item Function

No.
7 Turn Signal Lever Turn signal lever is mounted on the right side of the steering column.
PUSH it FORWARD for a left side turn signal.
PULL it BACKWARD for a right side turn signal. When operating the turn
signal lever, the red light in the lever blinks.
8 Electronic Throttle Pedal controls the speed of the engine and is operated by the operator's right
Accelerator Pedal foot.
9 Brake Pedal Brake pedal is located left of the accelerator pedal. Pedal controls the appli-
cation of the service brakes.
10 Inching/Brake Pedal Inching/Brake pedal is located left of brake pedal. Slightly pushing inching/
brake pedal will apply service brakes, and further pushing will fully disengage
transmission.
NOTE: When releasing inching/brake pedal, transmission will only engage if
engine speed is below 1500 rpm.
67
Model Description
Figure 10. Controls
68
Model Description
Table 11. Controls and Switches on Armrest (See Figure 10)
Item Item Function

No.
1,2 Boom Control Lever Joystick movement controls the four functions of the boom.
Diagonal movement of the joystick controls two functions at the same time.
The joystick movements are as follows:
PULL back on joystick to raise the boom.
PUSH FORWARD on joystick to lower the boom.
PUSH joystick to left to retract the boom.
PUSH joystick to right to extend the boom.
3 Retract/Extend PUSH the left side of the switch to retract the container attachment to 20 foot
Control Switch position.
PUSH the right side of the switch to extend the container attachment to 40
foot position.
69
Model Description
Table 11. Controls and Switches on Armrest (See Figure 10) (Continued)
Item Item Function

No.
4 Left Sideshift Button PUSH the button to sideshift container handler to the left.
4 Right Sideshift Button PUSH the button to sideshift container handler to the right
5 Right Hand/Left Hand PUSH top of switch for pile slope, left-hand side up.
Up Pile Slope Switch
PUSH bottom of switch for pile slope, right-hand side up.
6 Horn Button Operate button to activate horn.
70
Model Description
Item Item Function

No.
7 Forward/Backward Power PUSH the top of the switch to move the bottom side of the attachment forward.
Dampening Switch
PUSH the bottom of the switch to move the bottom side of the attachment
backward.
8 Twist Lock PUSH button to unlock twist locks.

Unlock Button
9 Fold/Unfold Front Legs PUSH the RH side of the switch to move the front legs to the vertical/down
(IH Trucks Only) position.
PUSH the LH side of the switch to move the front legs to the horizontal/up
position.
10 Fold/Unfold Rear Legs PUSH the RH side of the switch to move the rear legs to the vertical/down
(IH Trucks Only) position.
PUSH the LH side of the switch to move the rear legs to the horizontal/up
position.
71
Model Description
Item Item Function

No.
11 Clamp/Unclamp Right PUSH the front side of the switch to clamp the RH legs.
Legs Switch (IH Trucks
PUSH the rear side of the switch to unclamp the RH legs.
Only)
12 Clamp/Unclamp Left PUSH the front side of the switch to clamp the LH legs.
Legs Switch (IH Trucks
PUSH the rear side of the switch to unclamp the RH legs.
Only)
13 Twist Lock PUSH on top of the switch to lock the twist locks.
Lock/Unlock
PUSH on the bottom of the switch to unlock the twist locks.
Switch
72
Model Description
Item Item Function

No.
14 Sliding Cab Option PUSH on top of the switch to slide the cab FORWARD.
PUSH on the bottom of the switch to slide the cab BACKWARD.
Do not operate while the truck moves.
15 Front Window Washer PUSH on bottom of switch to turn the front window washer ON for timed wash/
Switch wipe operation. The wash operation will continue as long as the button of the
switch is being pushed.
16 Rear Window Wiper and This switch controls the rear window wiper and washer.
Washer Switch
PUSH bottom of switch to move the switch from OFF to position 1 and 2.
Release the button to return from position 2 to position 1.
PUSH top of switch to return the switch from position 1 to OFF.
In position 1, the rear windshield wiper is ON.
In position 2, the rear windshield wiper and washer are ON.
73
Model Description
Item Item Function

No.
17 Top Window Wiper and This switch controls the top window wiper and washer.
Washer Switch
PUSH bottom of switch to move the switch from OFF to position 1 and 2.
Release the button to return from position 2 to position 1.
PUSH top of switch to return the switch from position 1 to OFF.
In position 1, the top window wiper is ON.
In position 2, the top window wiper and washer are ON.
18 Front Window Wiper Switch This switch controls the front window wiper.
PUSH bottom of switch to move the switch from position 2 to OFF and position
1.
PUSH top of switch to move the switch from position 1 to OFF and position 2.
In position 1, the front window wiper is ON for continuous operation.
In position 2, the front window wiper is ON for intermittent operation.
74
Model Description
Item Item Function

No.
19 Pre-Clamp (IH Trucks PUSH the RH side of the switch to place the shoes of the rear legs in position
Only) to approach the load.
PUSH the LH side of the switch to retract the preposition of the rear legs.
20 Hydraulic Stop (Optional) PUSH the LH side of the switch to release the hydraulic stop and allow exten-
sion or retraction of the extension beams.
PUSH the RH side of the switch when one of the extension beams is close to
the desired end position.
21 Joystick, Rotation of Rotation of the joystick controls rotation of the attachment. Rotate joystick
Attachment clockwise for attachment rotation clockwise. Rotate joystick counterclockwise
for attachment rotation counterclockwise.
The attachment will rotate until the 12° rotation limit. To rotate further to −95°
or +185°, then push the override push button on the side console and operate
the rotation function on the joystick to rotate the attachment beyond the 12°
initial rotation limit. See Figure 10.
75
Model Description
LLMS Configuration for Trucks With or Without Stabilizer

Item Trucks Without Stabilizer Trucks With Stabilizer
SLIM Display (See Figure 11) Standard N/A
VIEW Display (See Figure 12) Option Standard
LLMS (Longitudinal Load Moment Indicator) If the green light is OFF, the LLMS will disable the derricking,
Indicator Lights extension, and the cab movement forward functions.
Have the LLMS repaired if the green light is OFF during
LLMS Check at Startup
operation.
At each startup the LLMS performs a self diagnostic test. The
Do not operate the truck with a load when the green light is
buzzer, the green, amber and red light on the display unit
OFF.
must be ON during a 1 second check, to confirm proper
functioning of the system, buzzer and lights. Have the LLMS Red Indicator Light
repaired if one or more lights or the buzzer are OFF during
The red indicator light is ON when the LLMS detects a sit-
startup.
uation requiring immediate action. The buzzer will be ON.
During startup the View screen will also show the date of the
Read the display to establish whether the maximum allowa-
software version and the truck model.
ble capacity has been reached or if an alarm situation has
Green Indicator Light been detected. See below explanation.
The green indicator light confirms proper functioning of the The derricking, extension and the cab movement forward
system and must always be ON. functions are disabled.
76
Model Description
Maximum Allowable Capacity Read the display to establish whether more than 90% of the
allowable capacity has been reached or if an alarm situation
If the actual load moment exceeds 90%, or when maximum
has been detected. See above explanation.
allowable capacity has been reached, decrease the load
moment as soon as circumstances allow by retracting the The amber indicator light is flashing when one or more sen-
boom. Operate smoothly to minimize dynamic forces. sors of the LLMS have a failure.
Alarm Situation The red indicator light and the buzzer will be ON. The der-
ricking, extension and the cab movement forward functions
If an alarm situation has been detected, do not operate the
are disabled. Rectify the alarm code displayed on the screen.
truck with a load. Look up the alarm code in Table 18 and
Do not operate the truck with a load when the amber light is
either follow the mentioned corrective action or call your
flashing.
dealer to have the alarm situation rectified.
Amber Indicator Light
The amber indicator light is ON when the LLMS warns for
situations requiring extra attention. The buzzer will be ON.
77
Model Description
A. LLMS SLIM DISPLAY B. NORMAL OPERATION SCREEN C. ALARM CONDITION SCREEN
Figure 11. LLMS Slim Display Unit
78
Model Description
Table 12. LLMS Slim Display Unit (See Figure 11)
Item Item Function

No.
1 Calibration Buttons DO NOT push these buttons. If these buttons have been pushed acci-
dently, the normal operation screen can be retrieved by switching the key
switch to OFF, and then to ON again.
2 Red Indicator Light When the red indicator light is ON, the LLMS detects a situation requiring
immediate action. Take appropriate action as indicated under LLMS indi-
cator lights.
3 Amber Indicator Light When the amber indicator light is ON, the LLMS warns for situations
requiring extra attention. Take appropriate action as indicated under
LLMS indicator lights.
4 Green Indicator Light The green indicator light confirms proper functioning of the system and
must always be ON. If the green light is OFF, the LLMS will disable the
derricking, extend, and cab movement forward functions. Have the LLMS
repaired if the green light is OFF during operation. DO NOT operate the
truck with a load when the green light is OFF.
5 Load Percentage Bar This graphic bar shows the actual load moment as a percentage of the
maximum allowable load moment for the actual load position.
6 Boom Length Indicates the distance in meters, which the inner boom has extended. The
indicated length varies between 0 to 6.6 m (0 to 236.2 in.).
79
Model Description
Table 12. LLMS Slim Display Unit (See Figure 11) (Continued)
Item Item Function

No.
7 Actual Load Indicates the actual weight of the container, in metric tons.
8 Maximum Load Indicates the maximum allowable load in metric tons for the actual load
position.
9 Height of the Spreader Indicates the actual distance between the twist locks and ground level, in
meters.
10 Load Radius Indicates the actual distance between the center of the spreader and the
front of the drive wheels in meters.
11 Angle of the Boom Indicates the boom angle in degrees, which can vary between 0° and 59°.
12 Alarm Code When the LLMS detects a fault condition, an alarm code is displayed at
the location where normally items 5, 6, and 9 are shown. The LLMS will
no longer function properly when an alarm code is displayed. DO NOT
operate the truck with a load. Call a trained mechanic to have the LLMS
repaired. See Table 18 for an explanation of the most common alarm
codes.
13 LLMS Slim Display The LCD-display shows actual data of the LLMS. The upper screen shows
an alarm code if an alarm condition exists.
80
Model Description
A. LLMS SCREEN WITHOUT STABILIZER. SEE FIGURE 13. C. LLMS SCREEN WITH STABILIZER. SEE TABLE 16.
B. ENGINE SCREEN. SEE TABLE 15. D. STABILIZER SCREEN. SEE TABLE 17.
Figure 12. LLMS View Display Unit
81
Model Description
Table 13. LLMS View Display Unit (See Figure 12)
Item Item Function

No.
1 Display Scroll Button PUSH button F1 to scroll between the different display screens.
2 Stabilizer UP Button PUSH button F2 to move the stabilizer up.
(Stabilizer Option)
3 Stabilizer DOWN Button PUSH button F3 to move the stabilizer down.
(Stabilizer Option)
4 Brightness Increase Button PUSH button F4 to increase brightness of the screen.
5 Brightness Decrease Button PUSH button F5 to decrease brightness of the screen.
6 Green Indicator Lights The green indicator light confirms proper functioning of the system and must always
be ON. If the green light is OFF, the LLMS will disable the derricking, extend, and
the cab movement forward functions. Have the LLMS repaired if the green light is
OFF during operation. DO NOT operate the truck with a load when the green light
is OFF.
7 Amber Indicator Light When the amber indicator light is ON, the LLMS warns for situations requiring extra
attention. Take appropriate action as indicated under: LLMS Indicator Lights.
8 Red Indicator Light When the red indicator light is ON, the LLMS detects a situation requiring immediate
action. Take appropriate action as indicated under: LLMS Indicator Lights.
82
Model Description
Table 13. LLMS View Display Unit (See Figure 12) (Continued)
Item Item Function

No.
9 Calibration Buttons DO NOT push these buttons. If these buttons have been pushed accidently, the
normal operation screen can be retrieved by switching the key switch to OFF, and
then to ON again.
10 Display Screen The display can show different screens depending on the presence of the operational
stabilizers.
For trucks without stabilizer, the screen will scroll between LLMS Screen and Engine
Screen by pushing button F1. See Figure 10.
For trucks with stabilizer, push button F1 to scroll from LLMS With Stabilizer Screen,
to Engine Screen, to Stabilizer Screen. See Figure 15, Figure 14 and Figure 16.
Explanations of the screens Figure 13 until Figure 16 are on Table 14 until
Table 17.
83
Model Description
Figure 13. LLMS Screen for Trucks Without Stabilizer
84
Model Description
Table 14. LLMS Screen for Trucks Without Stabilizer (See Figure 13)
Item Item Function

No.
1 Load Percentage Bar This graphic bar shows the actual load moment as a percentage of the maximum allowable
load moment for the actual load position.
2 Height of the Spreader Indicates the actual distance between the twist locks and ground level, in meters.
3 Boom Length Indicates the distance in meters, which the inner boom has extended. The indicated length
varies between 0 to 6.6 m (0 to 236.2 in.).
6 Load Radius Indicates the actual distance between the center of the spreader and the front of the drive
wheels, in meters.
7 Maximum Load Indicates the maximum allowable load in metric tons for the actual load position.
8 Alarm Code When the LLMS detects a fault condition, the LLMS will no longer function properly and
an alarm code is displayed. DO NOT operate the truck with a load. Call a trained mechanic
to have the LLMS repaired. See Table 18 for an explanation of the most common alarm
codes.
9 Calibration Information During calibration additional information is provided to assist with the calibration process.
85
Model Description
Figure 14. Engine Screen for Trucks With or Without Stabilizer
86
Model Description
Table 15. Engine Screen for Trucks With or Without Stabilizer (See Figure 14)
Item Item Function

No.
1 Engine RPM Gauge Indicates the Engine RPM.
2 Travel Speed Gauge Indicates the travel speed.
3 RH Derricking Cylinder, Rod Pressure Indicates the actual pressure at the rod side of the RH derricking cylinder,
in bars.
4 RH Derricking Cylinder, Piston Pressure Indicates the actual pressure at the piston side of the RH derricking cyl-
inder, in bars.
5 Alarm Code If an alarm situation has been detected, do not operate the truck with a
load. Look up the alarm code in Table 18 and follow the mentioned cor-
rective action or call your dealer to have the alarm situation rectified.
6 LH Derricking Cylinder, Rod Pressure Indicates the actual pressure at the rod side of the LH derricking cylinder,
in bars.
7 LH Derricking Cylinder, Piston Pressure Indicates the actual pressure at the piston side of the LH derricking cyl-
inder, in bars.
87
Model Description
Figure 15. LLMS Screen for Trucks With Stabilizer
88
Model Description
Table 16. LLMS Screen for Trucks With Stabilizer (See Figure 15)
Item Item Function

No.
1 Load Percentage Bar This graphic bar shows the actual load moment as a percentage of the
Maximum allowable load moment for the current load position.
3 Maximum Load Indicates the maximum allowable load in metric tons for the actual load
position.
4 Load Radius Indicates the distance between the center of the spreader and the front
of the drive wheels, in meters.
5 Boom Length Indicates the distance in meters, which the inner boom has extended. The
indicated length varies between 0 to 6.6 m (0 to 236.2 in.).
7 Height of the Spreader Indicates the actual distance between the twist locks and ground level, in
meters.
8 Park Brake Warning Light The park brake warning light is ON, when the parking brake is applied.
9 Speed Limit Warning Light This warning light is ON to signal that the speed limiter is switched ON.
When the Load Radius is less than 1.3 m (4.3 ft), the speed limit is
switched ON.
89
Model Description
Table 16. LLMS Screen for Trucks With Stabilizer (See Figure 15) (Continued)
Item Item Function

No.
10 Alarm Code If an alarm situation has been detected, do not operate the truck with a
load. Look up the alarm code in Table 18 and follow the mentioned cor-
rective action or call your dealer to have the alarm situation rectified.
11 Calibration Information During calibration additional information is provided to assist with the cal-
ibration process.
12 Brightness Decrease Icon Refers to button F5.
13 Stabilizer/Drive Mode Indicator Light A stabilizer symbol is shown, when all requirements for the proper use of
the stabilizer are met. The LLMS refers to the capacities that relate to
"stabilizer applied".
A tire symbol is shown when all requirements are met to drive the Reach-
Stacker. The LLMS refers to the capacities that relate to "stabilizer not
applied". The indicator will turn into yellow when there is an in between
situation.
Correct the situation that prevents the system from moving into stabilizer
mode or drive mode.
14 Brightness Increase Icon Refers to button F4.
15 Steering Applied Warning Light This warning light is ON when the steering wheel is being turned, while
the stabilizer is applied.
90
Model Description
Item Item Function

No.
16 Stabilizer Allowed to Move DOWN If the park brake is applied and truck speed is zero, the stabilizer is allowed
Indicator Light to move down and the background color of this icon will be light grey. If
the stabilizer is NOT allowed to move down, the background color will be
dark grey. If stabilizer movement is allowed and the stabilizer DOWN but-
ton (F3) is pushed, the background color turns green, and the icon turns
red.
17 Stabilizer Allowed to Move UP If the stabilizer is allowed to move up, the background color of this icon
Indicator Light will be light grey. If the stabilizer is NOT allowed to move up, the back-
ground color will be dark grey. If stabilizer movement is allowed and the
stabilizer UP button (F2) is pushed, the background color turns green,
and the icon turns red.
18 Load Difference Stabilizer Cylinders This graphic bar shows the difference in load weight being taken by the
two stabilizer cylinders. When the load weight is centered, the middle of
the graphic bar will be illuminated green. If a yellow and/or red section of
the graphic bar is illuminated, use the sideshift function to center the load
weight.
19 Display Scroll Icon Refers to button F1.
91
Model Description
Item Item Function

No.
20 Left Stabilizer Cylinder Fully Retracted The background of this indicator is green when the left stabilizer cylinder
Indicator Light is fully retracted. DO NOT move the ReachStacker when this indicator
has a light grey background. Investigate the cause of the warning and
correct.
21 Right Stabilizer Cylinder Fully Retracted The background of this indicator is green when the right stabilizer cylinder
Indicator Light is fully retracted. DO NOT move the ReachStacker when this indicator
has a light grey background. Investigate the cause of the warning and
correct.
92
Model Description
Figure 16. Stabilizer Screen for Trucks With Stabilizer
93
Model Description
Table 17. Stabilizer Screen for Trucks With Stabilizer (See Figure 16)
Item Item Function

No.
1 Left Stabilizer Cylinder Indicates the pressure in the left stabilizer cylinder, in bars.
Pressure
2 Right Stabilizer Cylinder Indicates the pressure in the right stabilizer cylinder, in bars.
Pressure
3 Steering Pressure Indicates the pressure in the steering system, in bars.
4 Rod Pressure Stabilizer Indicates the pressure at the rod side of the stabilizer cylinders, in bars.
Cylinders
5 Alarm Code When the LLMS detects a fault condition, the LLMS will no longer function properly and
an alarm code is displayed. DO NOT operate the truck with a load. See Longitudinal
Load Moment Indicator (LLMI) System 1900 SRM 1256 for an explanation of the
fault code and rectify accordingly. See Table 18 for an explanation of the most common
fault codes.
6 Stabilizer Allowed to Move If the stabilizer is allowed to move down, the background color of this icon will be light
DOWN Indicator Light grey. If the stabilizer is NOT allowed to move down, the background color will be dark
grey. If stabilizer movement is allowed and the stabilizer DOWN button (F3) is pushed,
the background color turns green and the icon turns red.
94
Model Description
Table 17. Stabilizer Screen for Trucks With Stabilizer (See Figure 16) (Continued)
Item Item Function

No.
7 Stabilizer Allowed to Move If the stabilizer is allowed to move up, the background color of this icon will be light
UP Indicator Light grey. If the stabilizer is NOT allowed to move up, the background color will be dark
grey. If stabilizer movement is allowed and the stabilizer UP button (F2) is pushed, the
background color turns green and the icon turns red.
95
Model Description
Table 18. Common LLMS Alarm Codes
Code Alarm Code Description Corrective Action

24 Too high pressure difference between the Check if the load is centered and center if necessary. The alarm normally
derricking cylinders at the piston side. goes off within a few seconds after applying the derricking up function.
Have the hydraulic system inspected in case the alarm stays on or when
this occurs with a high frequency.
25 Too high pressure difference between the Check if the load is centered and center if necessary. The alarm normally
derricking cylinders at the rod side. goes off within a few seconds after applying the derricking up function.
Have the hydraulic system inspected in case the alarm stays on or when
this occurs with a high frequency.
59 Stabilizer is NOT fully retracted and park Retract the stabilizer completely before driving the ReachStacker. Apply
brake is NOT applied. the park brake before using the stabilizer.
60 Stabilizer is NOT fully retracted and steer- Retract the stabilizer completely before driving the ReachStacker. DO
ing function is in use. NOT turn the steering wheel when the stabilizer is (partially) extended.
334 Too high pressure difference between left Check ground condition under stabilizer plate. Remove obstacles or fix
and right stabilizer cylinder. potholes. Check if load is centered and center if necessary.
335, Incorrect pressure values in stabilizer cyl- Apply stabilizers again. If the problem persist have the stabilizer system
336 inder inspected.
340 Pressure rod side stabilizer cylinder is too Apply stabilizers again. If the problem persist have the stabilizer system
high. System switches to the standard inspected.
capacity mode.
96
Model Description
Table 18. Common LLMS Alarm Codes (Continued)

1, 30, Load Moment Controller error DO NOT operate the truck with a load. Contact the service department.
31,
150,
151,
152,
153,
160,
161,
162,
198,
310,
350
thru
356
97
Model Description

8 thru Derrick cylinder pressure sensor error DO NOT operate the truck with a load. Contact the service department.
11, 18 Have a service technician check the wiring and connectors of the pressure
thru 21, sensors.
165,
166,
170
thru
178,
200
thru
219
98
Model Description

4, 5, Boom angle and length sensor error DO NOT operate the truck with a load. Contact the service department.
36, 37, Have a service technician check the wiring and connectors of the boom
120 angle and length sensor.
thru
123,
180,
181,
185,
190
thru
196,
220
thru
224,
230
thru
241
99
Model Description

50 thru Stabilizer cylinder pressure sensor error DO NOT operate the truck with a load. Contact the service department.
55, 320
thru
325,
330,
331,
333
56, 57 Steering pressure sensor error DO NOT operate the truck with a load. Contact the service department.
62, 63, Joystick error DO NOT operate the truck with a load. Contact the service department.
64
100
Model Description
Figure 17. Container Handler Control Box
101
Model Description
Table 19. Container Handler Control Box (See Figure 17)
Item Item Function

No.
1 Left Amber LED (Light Emitting Diode) Indicates attachment is seated on the left side.
2 Green LED Indicates that all twist locks are in the locked position.
3 Red LED Indicates that all twist locks are in the unlocked position.
4 Right Amber LED Indicates attachment is seated on the right side.
5 Light Sensor Detects the amount of light on the container handler control box and adjusts
the brightness of the container handler control box to obtain maximum visi-
bility of the LED for the operator.
6 Blue LED Indicates that over-lowering interrupt function or lift interrupt function is acti-
vated.
7 Instruction Reference Label Read the section System Override before operating the override push button.
8 Override Push Button This button allows overriding different systems that normally prevent entering
certain hazardous situations. To override systems, the Override Key Switch
must be enabled, the Override Button must be pushed and the relevant func-
tion control must be operated simultaneously.
9 Control Box Fuse The fuse is located at the rear of the container handler control box.
24VDC-0.315AT.
10 Override Counter Counter indicates the number of times the override function has been used.
102
Model Description
Table 19. Container Handler Control Box (See Figure 17) (Continued)
Item Item Function

No.
11 Volume Switch for Audible Alarm Is used to adjust the volume of the audible alarm for the twist locks.
12 Override Key Switch Enables or disables the override push button.
Audible Alarm (not shown) The audible alarm provides an acoustic signal when the blue LED is ON. The
buzzer can be switched ON or OFF. When switched ON, the volume can be
adjusted to suit the operator. When the override function is selected, the buz-
zer beeps intermittently at maximum volume.
103
Model Description
Table 20. Container Handler Indicator Light Descriptions
Indicator Light Indicator Light ON Indicator Light OFF Indicator Light FLASHING
Color/Location
Amber, Left-hand The left-hand seated pins are The left-hand seated pins are One of the left-hand seated sen-
seated. NOT seated. sors is faulty or incorrectly adjus-
ted.
Green The twist locks are in the locked The twist locks on one or both One of the locked sensors is
position. sides are NOT in the locked posi- faulty or incorrectly adjusted.
tion.
Red The twist locks are in the The twist locks on one or both One of the unlocked sensors is
unlocked position. sides are NOT in the unlocked faulty or incorrectly adjusted.
position.
Amber, Right-Hand The right-hand seated pins are The right-hand seated pins are One of the right-hand seated
seated. NOT seated. sensors is faulty or incorrectly
adjusted.
NOTE: If one or more indicator lights are flashing, immediately repair the attachment.
104
Model Description
Table 21. Automatic Greasing System Display (See
Figure 18)
Item Item Function

No.
1 Switch Button Button for service personnel to
select duty mode and test modes.
2 Display Indicates selected mode and
occurring fault codes.
3 Decimal Dot Indicates actual greasing cycle
stage.
4 Green LED Indicates that the greasing system
is activated.
5 Yellow LED Is ON at startup and when the
grease level in the reservoir is low.
Call service for a soon refill when
the reservoir is low.
6 Red LED Is ON at startup and when there is
Figure 18. Automatic Greasing System Display a malfunction. Call service for
(Optional) repair when the red LED is ON.
105
Operating Procedures
General WARNING
FIRE HAZARD
Know Your ReachStacker
The hot engine surfaces and exhaust of internal com-
bustion engine powered ReachStacker can present fire
WARNING hazards when operating in areas containing flammable
EXHAUST GASES gases, vapors, liquids, dusts, or fibers. Engine and
Exhaust from internal combustion engines contains car- exhaust component surface temperatures can exceed
bon monoxide and other harmful chemicals. Carbon the ignition temperatures of common solvents, fuels, oil,
monoxide is a colorless, odorless poison and can cause paper, and other organic materials (wood, agricultural
unconsciousness or death without warning. Long-term grass/grain, cotton, wool, etc.). Exhaust emitted sparks
exposure to exhaust or chemicals in the exhaust can can ignite these materials as well. Engine and exhaust
cause cancer, birth defects, and other reproductive surface temperatures increase after engine shutoff, pre-
harm. Avoid exposure to engine exhaust. senting increased fire hazard. Check the engine com-
If engines are operated in confined spaces, maintain partment immediately following truck operation in areas
adequate ventilation or vent exhaust to the outside. DO containing combustible dusts, fibers, or paper and
NOT exceed applicable air contaminant limits. remove any foreign materials.
Follow the inspection and maintenance schedule and Operate the ReachStacker only in areas that have been
procedures in this manual. DO NOT alter exhaust, igni- approved for ReachStacker operation.
tion, or fuel systems. Only the designated types of approved ReachStacker
may be used in areas classified as hazardous by the
authority having jurisdiction. Areas classified as haz-
ardous must be identified by signs to show the type of
106
approved ReachStacker required for operation in the the load (container) must be balanced by the weight of the
area. Modifications or poor maintenance can result in ReachStacker. The location of the center of gravity of both
the ReachStacker being unsuitable for operation in the ReachStacker and the load is also a factor.
areas classified as hazardous.
This basic principle is used for picking up a load. The ability
The ReachStacker is designed primarily to pick up and move of the ReachStacker to handle a load is discussed in terms
containers and trailers. The basic ReachStacker has a of center of gravity and both forward and side stability.
spreader to engage the load. The boom lifts the load so that
it can be moved and stacked. Stability and Center of Gravity
The ReachStacker can also be equipped with tie points for The center of gravity (CG) of any object is
ropes or chains to be used with a sling. If ReachStacker is the single point about which the object is
used in conjunction with a sling, load swing must be limited. balanced in all directions.
Secure load to the ReachStacker frame with ropes or chains.
Every object has a CG. When the Reach-
In order to understand how the ReachStacker can pick up a Stacker picks up a load, the ReachStacker
load, you must first know some basic things about the Reach- and load have a new combined CG.
Stacker.
The ReachStacker is
based on the principle of
two weights balanced on
opposite sides of a pivot
(fulcrum). This is the
same principle used for a
seesaw. In order for this principle to work for a ReachStacker,
107
A. CG LOAD B. COMBINED CG C. CG ReachStacker
The center of gravity, and therefore the stability of the loaded

A. CG LOAD B. CG ReachStacker C. COMBINED CG
ReachStacker, is affected by a number of factors such as
The stability of the ReachStacker is determined by the loca- size, weight, shape, and position of the load; the height to
tion of its CG, or if the ReachStacker is loaded, the combined which the load is elevated; the amount the boom is extended
CG. and raised; tire pressure; and the dynamic forces created
when the ReachStacker is moving. These dynamic forces
The ReachStacker has moving parts and, therefore, has a are caused by things like acceleration, braking, turning, and
CG that moves. The CG moves forward and back as the operating on uneven surfaces or on an incline. These factors
boom is extended or retracted. The CG moves up and down must be considered when traveling with an unloaded Reach-
as the boom is raised and lowered. Stacker, as well, because an unloaded ReachStacker can
also tip over to the side.
108
In order for the ReachStacker to be stable (not tip over for- If the CG moves forward of the drive axle, the ReachStacker
ward or to the side), the CG must stay within the area of the will tip forward. If the CG moves outside of the line repre-
ReachStacker represented by a triangle drawn between the sented by the lines drawn between the drive wheels and the
drive wheels and the pivot of the steering axle. steering axle pivot, the ReachStacker will tip to that side.
Capacity (Weight and Load Center)
The capacity of the ReachStacker is shown on the capacity
chart above the nameplate. The capacity is the maximum
load that the ReachStacker can handle for the indicated load
position. The load must weigh less than the maximum weight
for a load as shown on the capacity chart. See Figure 19.
The operator must be able to determine whether or not a load
is within the capacity of the ReachStacker before the load is
A. DRIVE AXLE C. CG - ReachStacker WILL TIP handled.
B. STEERING AXLE OVER
109
A. NAMEPLATE B. SAMPLE CAPACITY CHART
Figure 19. Nameplate and Capacity Chart
110
LLMS (Longitudinal Load Moment Indicator) moment for the load position. The LLMS prevents the actual
load moment from exceeding the maximum allowable load
WARNING moment by disabling the boom extend and boom derricking
For the LLMS to operate as designed, the ReachStacker down functions. The LLMS Indicator lights warn the driver
must be stationary on level and stable ground without when the maximum allowable load moment has been
the boom fully retracted. The LLMS must not be over- reached, or is about to be reached. The driver has to correct
ridden. The LLMS is intended only to warn the operator the situation by retracting the boom. The LLMS does not take
of inadequate stability in the longitudinal plane in the dynamic forces into account. Before moving the Reach-
forward direction when performing loading and placing Stacker with a load, reduce the required capacity by retract-
functions. ing the boom as far as possible. Containers should be
handled over a container stack or near ground level. Mid-air
The LLMS is not a substitute for good judgment and manipulation (extending boom and/or down-derricking)
experience. Do not rely on the LLMS to prevent instabil- which increases the load moment should be avoided. If
ity. Always observe the accepted safe operating proce- ReachStacker is used in conjunction with a sling, load swing
dures for the ReachStacker. must be limited by securing the load to the ReachStacker
The ReachStacker is equipped with a LLMS. During opera- frame with ropes or chains.
tion the LLMS uses the weight and the position of the load to Detailed Load Moment information is continuously visible on
determine the actual load moment. This actual load moment the LLMS screen.
is continuously compared with the maximum allowable load
111
Inspection Before Operation • Pre-cleaner for the air filter.

• Condition of attachments and operator's compartment.
Checks With the Engine Stopped • Check for presence and readability of safety labels. See
Figure 3.
Inspect the ReachStacker before use and every 8 hours or
daily as described in the Maintenance section of this Oper- • Leaks from the engine, transmission, hydraulic system,
ating Manual. Make sure that the area around the Reach- and fuel system.
Stacker is clear before making any operational checks. Use • Condition of wheels and tires. Check the air pressure in
caution when making these checks. the pneumatic tires.
Before using the ReachStacker, make the following checks: • Seat belt fastens correctly. Retractor operates correctly.
• Fuel level. • Mirrors are clean and adjusted.
• Oil level in the engine and hydraulic tank. • Windows are clean.
• Coolant level in the cooling system and condition of the
drive belts. WARNING
Report damage or faulty operation immediately. DO NOT
• Condition of the engine compartment. Ensure all surfaces operate a damaged or defective ReachStacker. A Reach-
are free of oils, lubricants, fuel, and organic dusts or fibers Stacker will only do its job when it is in proper working
(paper, wood, cotton wool, agricultural grass/grain, etc.). order. If repairs are required, install a tag in the opera-
Remove all foreign materials. tor's area stating DO NOT operate and remove the key
• Condition of the radiator. Clean if necessary. from the key switch.
112
Starting Procedures b. If equipped, put the directional control lever for the
transmission in the N (NEUTRAL) position.
Do not start or operate the ReachStacker, including any of
its functions or attachments, from any place other than the c. Completely depress the inching/brake pedal.
designated operator's position. If equipped, be sure cab door If lift truck is equipped with the optional OPS:
is secured in the closed position before starting lift truck
operations. 1. The following sequence must be followed for engine to
start.
WARNING a. Operator must be in seat.
DO NOT use starting fluid (ether) or other flammable liq-
uids as starting aids. The engine is equipped with an b. Seat belt must be fastened.
electric heater for a starting aid. Use of ether or other c. Make sure parking brake is applied.
flammable liquids can cause a fire and explosion, caus-
ing serious personal injury and engine damage. 2. Turn key to the ON position. Wait until all warning lights
are OFF.
CAUTION 3. Turn the key to the START position to engage the starter.
DO NOT engage the starter for more than 10 seconds at Allow the key to return to the ON position when the engine
a time. If the engine does not start, turn the key switch starts. Only engage the starter for a maximum of 10 seconds.
to OFF. Wait two minutes before engaging the starter
again. 4. If the engine does not start after four attempts, get help
from authorized service personnel.
If lift truck is equipped with the standard OPS:
5. With the engine running at idle, check the gauges and
1. Either: indicator lights for correct operation. See Controls, Instru-
a. Apply the parking brake. ments, Indicators, and Switches section in this Operating
Manual.
113
6. Check for engine fault codes. The ECM (Engine Control proportional to the hydraulic oil temperature. The fault code
Module) controls and monitors the engine and records fault display will show 'hCold'. At −20 °C (−4 °F), the engine speed
conditions using fault codes. In case of an active fault, the is limited to 1000 rpm. Above −5 °C (23 °F), the controller
Engine Warning Light or the Engine Stop Warning Light will does not limit engine speed. Apply hydraulic functions to
come ON. See Table 5. raise hydraulic oil temperature. For a quicker rise of hydraulic
oil temperature, apply hydraulic functions against relief.
These codes may appear when the following occurs:
• The Engine Warning Light will come ON when operating Exhaust System Regeneration (Tier 4i/Stage
conditions are getting near the maximum permissible val- IIIB Engines Only)
ues, and the ECM may decrease engine performance.
To comply with regulations, the Tier 4i/Stage IIIB trucks are
Check and monitor dashboard gauges and warning lights
provided with a diesel particulate filter. It's function is to filter
to take appropriate action when needed.
solid particles and regenerate these particles into gaseous
• The Engine Stop Warning Light will come ON when oper- components that will not harm the environment. Regenera-
ating conditions are beyond the permissible values. Imme- tion of solid particles requires that the diesel particulate filter
diately switch OFF the engine. has reached an elevated temperature. Normal operation of
the truck ensures a high enough filter temperature resulting
In either case, read all active fault codes immediately by
in sufficient conversion of solid particles. Circumstances may
using the fault code display. See Table 5. Record each code.
require a forced regeneration, which is more often initiated
Refer to Table 6, for Additional Information. Early communi-
by the engine control system during operation of the truck. It
cation of the recorded fault code(s) to your Hyster lift truck
is also possible that the controller calls for a Stationary
dealer will assist them in preparing for a service call.
Regeneration Procedure to have the diesel particulate filter
Heating Hydraulic Oil regenerated. The description of this procedure is below.
When hydraulic oil temperature in the reservoir is below

−5 °C (23 °F), the hydraulic controller limits engine speed
114
Stationary Regeneration Procedure CAUTION

1. Move the truck to an area that allows high exhaust system The turbocharger can be severely damaged when
temperatures reaching 500 °C (932 °F). switching off a hot engine when the 3 to 5 minute idle
period is not performed.
2. Apply the park brake and let the engine run at idle speed.
4. Allow the turbocharger of the engine to cool down and to
3. Press and release the bottom of the Regeneration Control obtain the lowest possible turbo speed before stopping the
Switch to start the Stationary Regeneration Procedure. The engine. If engine coolant temperature is low to moderate,
Regeneration Inhibit Light will be OFF. keep the engine at lowest idle for 3 minutes before turning
4. The ECM will increase engine speed and will start the the key switch to OFF. If engine temperature is high, keep
regeneration process. the engine at lowest idle for at least 5 minutes before turning
the key switch to OFF.
5. When regeneration has been finished after 15 to 20
minutes, engine speed will drop to idle. The Diesel Particu- Derating and Automatic Shutdown Procedures
late Filter Light will be OFF.
NOTE: Should any warning light come on to signal derate,
The truck is now ready again for service. the operator should try to moderate the truck duty so that
shutdown is avoided if at all possible.
Manual Shutdown Procedures
Coolant Temperature
1. Place the ReachStacker on a solid, level surface.
If the coolant temperature reaches 107 °C (225 °F), the tor-
2. Apply parking brake.
que derate will start.
3. Put the shift lever for the transmission in the NEUTRAL
The engine will shut down 30 seconds after the coolant tem-
(N) position.
perature exceeds 113 °C (235 °F).
115
Intake Manifold Temperature and 15 minutes. To restart the engine, turn the switch to
OFF and follow the normal starting procedures.
If the intake manifold temperature reaches 117 °C (240 °F),
the torque derate will start. Operator Presence System (OPS)
The engine will shut down 30 seconds after the intake mani- The lift trucks covered in this manual are equipped with an
fold exceeds 123 °C (253 °F). Operator Presence System (OPS). Some lift trucks are
equipped with an optional Operator Presence System which
Engine Oil Temperature will not allow the truck to travel or operate hydraulic boom
If the oil temperature reaches 123 °C (252 °F), the torque functions unless the operator is in the seat and the seat belt
derate will start. is also fastened.
The engine will shut down 30 seconds after the oil tempera- The OPS feature has an electrical switch in the seat which
ture exceeds 131 °C (265 °F). senses the presence of the operator. When the operator is
in the seat, the transmission can be engaged and hydraulic
Engine Oil Pressure functions can be operated. When the operator is absent, the
transmission will disengage and hydraulic boom functions
If the engine oil pressure is below the low limit for 10 seconds, cannot be operated. The OPS is designed with a slight delay
torque derate will start after 5 seconds. The engine will shut in the seat switch to allow the operator to reposition himself
down 30 seconds after torque derate is started. without disabling the transmission and all hydraulic func-
Empty Seat Engine Shutdown tions.
The engine shuts down if the operator is not on the seat dur- To check operation of the OPS, there must be no operator in
ing a certain time. This time has been set by the factory at the seat for at least 2.5 seconds. Verify the hydraulic func-
15 minutes and can be adjusted by your dealer between 5 tions do not operate and that the transmission is disengaged.
116
To check operation of the optional OPS, an additional check back position, the transmission will shift to NEUTRAL and
is required. With operator in the seat and seat belt NOT fas- the LLMS will limit the retract and derricking up functions.
tened for at least 2.5 seconds, verify the hydraulic boom
functions do not operate and the transmission is disengaged. Powered Sliding Cab System
If the OPS does not operate as expected, remove truck from During normal operation the cab can be moved by a switch
service until repairs are completed. that is located on the armrest. See Figure 10. The sliding cab
switch is only operational when the key switch is in the ON
To reset the OPS and allow full truck operation, the operator position and when both cab doors are closed. When the slid-
must be seated. For trucks equipped with the optional Oper- ing function is activated, a buzzer inside and a buzzer outside
ator Presence System, the seat belt must also then be fas- of the cab will sound.
tened. Engage the transmission using any of the following
actions: WARNING
• Depress the inching brake pedal more than 75%. Use the override switch only in emergency situations,
when there is an apparent failure of the door switches.
• Move the gear selector into the NEUTRAL position, and When the doors are open while the cab is moving, seri-
then move the gear selector into travel mode. ous damage to the truck and personal injury or death
Non-Power Sliding Cab System may occur.
To allow the sliding function in case of failed door sensors,
Components located in the engine compartment under the
an override switch on the side console must be pushed, in
cab can be accessed by moving the sliding cab. To move the
addition to the sliding cab switch.
cab, shut the doors, and release the two locks at the low rear
of the cab. Push against the cab to move it into the desired Sensors detect the actual position of the cab. If the cab is
position. To operate the ReachStacker, the cab must be NOT in the most rearward position, the LLMS limits the boom
locked in the full back position. If the cab is NOT in the full retract and derricking up functions. This prevents the cab
from being hit by the load. Forward movement of the cab is
117
interrupted if the position of the attachment is too close to the
cab.
The cab can also be moved by an external switch, which is
located under the battery cover, just above the battery dis-
connect switch. See Figure 20.
Push the switch to activate the rearward movement of the
cab. In order to allow forward cab movement by the external
switch, the key switch in the cab must be put in the ON posi-
tion.
The cab is equipped with an emergency stop button at the
front and rear side of the cab. Pushing either of these two
buttons interrupts the sliding cab movement.
1. SLIDING CAB SWITCH

2. BATTERY DISCONNECT SWITCH
Figure 20. Sealed Fuses
118
Automatic Greasing System (Optional)

The optional automatic greasing system provides most of the
Checks With the Engine Running
truck grease points with the grease. Not connected with the
automated greasing system are the cab door hinges, the WARNING
drive shaft, and the optional stabilizer, which still have to be FASTEN SEAT BELT
greased manually at the scheduled intervals. If ReachStacker Tips Over:
Verify correct operation daily by checking the LEDs on the • DO NOT Jump – Stay On Truck
automatic greasing system display and take appropriate
action when necessary. • Hold Firmly To Steering Wheel – Brace
Feet – Lean Forward And Away From
See Automatic Greasing System 8000 SRM 1533 for more Impact
information.
The seat belt is installed to help the operator
stay on the truck if the ReachStacker tips
over. IT CAN ONLY HELP IF IT IS FASTENED.
The operator must be aware that the Reach-
Stacker can tip over. There is a great risk that
the operator or someone else can be killed
or injured if trapped or hit by the Reach-
Stacker as it tips over. The risk of injury can be reduced
if the operator stays on the ReachStacker. If the Reach-
Stacker tips over do not jump off!
119
The SEAT BELT provides a means to help the operator keep • Check the operation of the transmission, the shift lever,
the head and torso substantially within the confines of the and accelerator pedal. Check that the audible reverse
truck frame and overhead guard if a tipover occurs. This pro- alarm operates when the shift lever is in the REVERSE
tection system is intended to reduce the risk of the head and position.
torso being trapped between the ReachStacker and the
• Check the operation of the service brakes and parking
ground, but it can not protect the operator against all possible
brake.
injury in a tipover.
• Check the operation of the steering system.
Make sure the area around the ReachStacker is clear before
starting the engine or making any operational checks. Be Operating Techniques
careful when making the checks. If the ReachStacker is sta-
tionary during a check, apply the parking brake and put the WARNING
transmission in NEUTRAL. Proceed carefully. Before operating the Reach-
Check the operation of the following functions as described Stacker FASTEN YOUR SEAT
in the Maintenance section: BELT.
• Check the operation of the horn, gauges, and indicator There are a number of operations,
lights. if not performed carefully, that can cause the Reach-
Stacker to tip. If you have not read the WARNING page
• Check the oil level in the powershift transmission when the in the front of this OPERATING MANUAL, do so NOW.
oil is at operating temperature. As you study the following information about how to
• Operate the boom and spreader functions to check for the properly operate a ReachStacker, remember the WARN-
correct operations. INGS.
120
Basic Operating Procedures ator through several driving and load handling operations
before the operator attempts to operate the ReachStacker
Many people make the mistake of thinking that operating this alone. A basic education in proper driving and load handling
ReachStacker is the same as driving an automobile. This is techniques is absolutely necessary to prepare the new oper-
not true. It is true that some ReachStacker operating proce- ator for proper defensive driving and to expect the unexpec-
dures are as simple and obvious as driving the family auto- ted.
mobile. (e.g. Look where you are going, start and stop
smoothly, etc.) But the ReachStacker is a special machine 2. Operate the ReachStacker only on firm and essentially flat
designed to do a much different job than an automobile. surfaces in areas that have been approved for ReachStacker
Because of the confined areas in which this ReachStacker operation.
operates and its other operating characteristics (like rear
wheel steering and tail swing), every operator must receive Certain areas contain hazardous flammable
additional training, even if they have a license to drive an gases, liquid, dust, fibers or other materials.
automobile. ReachStackers that are operated in these
areas must have special fire safety approval.
The following discussion lists basic procedures applicable to
ReachStacker operation. These areas must be designated to show the
type of ReachStacker approval required for operation in the
1. AUTHORIZED AND TRAINED area. Changes to special equipment or poor maintenance
OPERATOR ONLY. This means can make the ReachStacker lose its special approval.
the operator must be trained to drive
the ReachStacker and it means that
the operator must thoroughly under-
stand the procedures for Reach-
Stacker operation. It also means that a qualified person
experienced in ReachStacker operation must guide the oper-
121
WARNING Driving and Direction Changes

The ReachStacker is designed and These ReachStacker have a four-speed powershift trans-
intended for handling containers. mission. Operate the transmission as follows:
Do not lift or move people that are
outside of the cab. The shift lever for the transmission is on the left side of the
steering column. Push the shift lever FORWARD (F) to travel
FORWARD. Pull the shift lever back (R) to travel in
REVERSE. Move the shift lever to the center (N) position to
put the transmission in NEUTRAL. An audible reverse alarm
is activated whenever the shift lever is in the REVERSE
3. NO RIDERS. A ReachStacker is built for
position. The transmission controller (APC200) will NOT
only one person - the operator. It is dan-
allow gear engagement and/or direction changes if the
gerous for anyone to ride anywhere else on
engine speed is more than 1500 rpm or truck speed is more
the ReachStacker.
than 4 km/h (2.5 mph).
Range selection is by rotation of the handle of the shift lever.
Rotate the handle to one of the four ranges for automatic
shifting up and down through the ranges as described in Fig-
ure 9. All four speeds are available in the FORWARD or
4. Drive carefully, observe traffic rules and be in
REVERSE direction of travel as selected.
full control of the ReachStacker at all times. Be
completely familiar with all the driving and load To change directions, use the brake pedal to slow, less than
handling techniques in this OPERATING MAN- 4 km/h (2.5 mph), or stop the vehicle. Change directions with
UAL. the shift lever. The transmission will shift to NEUTRAL if a
reversal is attempted when the speed is too fast.
122
The ReachStacker has the capability of making directional Inching is the movement of the ReachStacker that allows a
shifts at travel speeds up to a walking pace, but the boom slow travel speed while keeping the engine speed high for
must not be raised and the load must be stable. If the Reach- fast operation of the lift mechanism.
Stacker is moving rapidly, slow to a walking speed before
changing the direction of travel.
NOTE: During the operation of the truck, the APC200 con-
troller may display transmission exceed codes on the hour-
meter and fault indicator display. These codes are shown in
Table 7.
In the event of an a transmission failure, contact your local
service representative.
Inching/Braking
A. FAST B. SLOW
WARNING
Inching requires coordinated movement of the inching/
brake pedal and the accelerator. New operators must
practice this procedure before attempting to handle
loads.
The ReachStacker has a brake pedal and a inching/brake
pedal. The brake pedal (middle pedal) applies only the
brakes. Slightly pushing the inching/brake pedal (left-hand
pedal) will apply the service brakes and, further pushing the
pedal, will fully disengage the transmission.
123
Steering (Turning) FEET, AND LEAN FORWARD AND AWAY FROM THE
POINT OF IMPACT.
WARNING
TRAVEL SLOWLY WHEN TURN- WARNING
ING. ReachStacker can tip over Failure to observe the tail swing area when making a turn
even at very slow speeds. The can injure or kill someone.
combination of speed and the
sharpness of a turn can cause a
tipover. A ReachStacker is less
stable when the boom is elevated,
with or without a load.
Most operators can understand the
need to be careful when handling loads but some operators
do not realize that a tipover can occur with an empty Reach-
Stacker because similar dynamic forces are present. In fact,
the ReachStacker will actually tip over easier sideward when
empty, than when loaded with the load lowered. A retracted
A. TAIL SWING
boom, off-center loads, and uneven ground will aggravate
these conditions. Because ReachStackers are designed to work in a relatively
small space, they can turn sharper than some other vehicles.
WARNING Most ReachStackers are steered by the rear wheels and the
IF THE ReachStacker TIPS OVER, DO NOT JUMP OFF! rear of the ReachStacker can move to the side very fast dur-
HOLD FIRMLY TO STEERING WHEEL, BRACE YOUR ing a turn. This movement is called tail swing. An operator
124
must be aware of tail swing and always check to make sure
the tail swing area is clear before turning.
Tail swing for ReachStackers is determined by the rear of the
boom because the rear of the boom can extend up to 0.5 m
(2.0 ft) behind the counterweight.
Do not turn on an incline. To reduce

the possibility of a tipover, a Reach-
Stacker must not be driven across an
incline.
When possible, keep both hands on
the steering wheel. During most load- When turning the ReachStacker from a wide aisle into a nar-
ing or unloading operations, the oper- row aisle, start the turn as close to the opposite stock pile as
ator steers with the left hand. The right hand is used to tail swing will permit. This action permits the ReachStacker
operate the boom and spreader controls. to enter the narrow aisle going straight ahead.
125
Traveling
WARNING
The ReachStacker can tip over forward when the load is
raised. Forward tipping is even more likely when the
boom is extended or lowered while traveling forward or
accelerating in reverse.
WARNING
IF THE ReachStacker TIPS OVER, DO NOT JUMP OFF!
HOLD FIRMLY TO STEERING WHEEL, BRACE YOUR 2. When traveling up or down a grade with a heavily loaded
FEET, AND LEAN FORWARD AND AWAY FROM THE ReachStacker, keep the load upgrade to maintain control.
POINT OF IMPACT.
1. Travel with the boom and spreader raised only enough for WARNING
visibility. Use the rear view mirrors for viewing along the sides of
the ReachStacker to observe the tail swing area. These
mirrors are an aid to the driver. Always look in the direc-
tion of travel to avoid damage to something or injury to
someone.
NOTE: Use extra care at intersections and other locations
where pedestrians can step into the path of travel of the
ReachStacker. Slow down when approaching blind intersec-
tions or turns and sound the horn. This alarm is to warn
126
pedestrians that there is a ReachStacker in the area and to
be alert to possible danger.
3. Watch out for pedestrians at all times.

Do not drive up to anyone standing in
front of an object.
4. Watch clearances, especially around
the load, boom and spreader and the tail
swing. A ReachStacker is designed to
work within a limited area. Serious acci-
dents can be caused by the boom or spreader hitting pipes,
7. Do not indulge in stunt driving.
wires or containers.
8. Do not pass another ReachStacker traveling in the same
5. Anytime the ReachStacker is moving keep arms, legs,
direction at intersections, blind spots or at other dangerous
etc., inside the operator's compartment. Arms and legs out-
locations.
side the machine can be injured during operation.
9. Stay away from the edge of the road. Keep the tires of the
6. Avoid bumps, holes, slick spots and loose materials that
ReachStacker, especially the steer tires, on the roadway. If
can cause the ReachStacker to swerve or tip. If unavoidable,
the tires are allowed to run off the edge of the travel surface
slow down.
and onto soft ground, the ReachStacker can tip over.
WARNING
Maintain a safe distance from the edge of docks, ramps,
platforms and other similar working surfaces. Watch the
tail swing.
127
ity. Always observe the accepted safe operating proce-
WARNING
dures for the ReachStacker.
Remember when traveling in the forward direction and
the steering wheel is turned to move the ReachStacker Each time the ReachStacker is started, the operator must
away from the edge of the dock the rear will swing check if the indicator lights for the LLMS function as indicated
toward the edge. This can cause the ReachStacker to fall in Table 12.
off the dock.
After the key switch is ON, the warning lights and audible
10. Stay away from the edge of docks. alarm will be on for approximately one second.
11. Under all travel conditions, operate the ReachStacker at Stabilizer Operation
a speed that will permit it to be brought to a stop in a safe
manner. Description
The Longitudinal Load Moment System (LLMS) Applying the stabilizers provides additional lifting capacity
with the boom extended. When picking up a load with the
WARNING boom extended, the operator can first try to lift it without using
the stabilizer. If the load is too heavy (red indicator light of
For the LLMS to operate as designed, the ReachStacker
the LLMS comes ON) the stabilizer can be applied to provide
must be stationary on level and stable ground without
additional lifting capacity. When depositing a container, the
the boom fully retracted. The LLMS must not be over-
View display will show the weight of the container. The load
ridden. The LLMS is intended only to warn the operator
chart will indicate if the capacity is sufficient for the distance
of inadequate stability in the longitudinal plane in the
(row) at which the container is to be deposited, or if it will be
forward direction when performing loading and placing
required to apply the stabilizer. Before applying the stabilizer,
functions.
position the ReachStacker as close and as aligned as pos-
The LLMS is not a substitute for good judgment and sible to the final position of the container.
experience. Do not rely on the LLMS to prevent instabil-
128
Activation of the stabilizer system is initiated by the operator Indicator light) will be yellow. When the stabilizer symbol is
by pushing buttons F2/F3 on the VIEW display. See shown at icon 13, all requirements for the proper use of the
Table 13. Before pushing the stabilizer DOWN button (F3), stabilizer are met and the LLMS will refer to the capacities
make sure there are no obstacles under the stabilizer plate that relate to "stabilizer applied".
and that the plate will be supported by a solid and level sur-
Returning to Drive Mode
face. Required conditions that allow the stabilizer to move
are as follows: When conditions are met to move the stabilizer up, the back-
ground color of icon 17 will be light grey. If the stabilizer is
• Park brake applied.
NOT allowed to move up, the background color will be dark
• Driving speed is zero. grey, and conditions have to be corrected. Push and hold the
Stabilizer UP Button (F2) until the tire symbol appears on the
• Load radius is at least 1.865 m (6.1 ft).
Stabilizer/Drive Mode Indicator light (item 13). If stabilizer
Applying the Stabilizer movement is allowed and the Stabilizer UP Button (F2) is
being pushed when allowed, the background color of item 17
When the above conditions are met, the stabilizer is allowed
is green, and the icon itself turns red. When the stabilizer has
to move down, and the background color of icon 16 will be
not reached the stabilizer UP position, icon 13 (Stabilizer/
light grey. See Figure 15. If the stabilizer is NOT allowed to
Drive Mode Indicator light) will be yellow. A tire symbol is
move down, the background color will be dark grey, and con-
shown, when all requirements are met to drive the Reach-
ditions have to be corrected. Push and hold the Stabilizer
Stacker and the LLMS refers to the capacities that relate to
Down Button (F3) until the stabilizer symbol appears on the
"stabilizer not applied".
Stabilizer/Drive Mode Indicator light (item 13). If stabilizer
movement is allowed and the stabilizer DOWN button (F3) is When the stabilizer is not completely up, an alarm will sound
being pushed, the background color of item 16 is green, and when the steering wheel is moved. This is to remind the
the icon itself turns red. When the stabilizer has not reached driver that he should not drive the ReachStacker.
the stabilizer down position, icon 13 (Stabilizer/Drive Mode
129
Load Handling, How to Handle Containers 6. Only handle loads within the rated capacity of the Reach-
Stacker. Refer to the nameplate and the capacity chart
The following discussion describes the use of the 20- to 40- mounted on the ReachStacker. See Figure 19.
foot extendable attachment used for handling containers.
7. Always be careful of winds while handling containers.
WARNING Strong wind force on raised containers can tip the Reach-
Failure to follow these instructions can cause serious Stacker. Do not stack containers in winds above 45 km/h
injury or death. (28 mph).
1. Follow these instructions and the operating, inspection How to Pick Up a Container
and maintenance instructions in the Maintenance Sched- NOTE: The attachment may only be used to lift 20 foot and
ule. 40 foot containers. If the attachment is equipped with stops,
2. Before using the container attachment, inspect the attach- then also 30 foot containers can be lifted.
ment for damage and make sure all of the controls operate 1. Retract the stops (optional) and adjust the length of the
as specified in Figure 9. attachment to the size of the container. Extend the stops
3. Always put the attachment in the center of the Reach- when the extension beams are close to the desired 30 foot
Stacker when not carrying a container. Use the sideshift position. Release the switch for extension / retraction when
function to put the attachment in the center position. the end position has been reached.
4. Use the sideshift function to keep the container as level as 2. Put the ReachStacker in a position so that the attachment
possible when carrying a container. is approximately centered with the container. Raise the
attachment high enough above the container to provide good
5. Watch the clearance around the whole length of the con- visibility. Move the ReachStacker as close as possible to the
tainer. stack of containers. Operate the side shift, rotate and boom
130
functions to position the attachment accurately over the con-
tainer corners.
3. When the attachment is aligned with the container, lower
the attachment so that the twist locks enter the corners of the
container. The amber lights under the boom and on the con-
tainer handler control box will be ON when all four corners of
the attachment are seated with the container.
4. If all four amber lights are NOT ON, CAREFULLY lift the
spreader just free of the container and readjust the position
of the spreader.
5. When seated, the twist locks will automatically be locked. NOTE: NEVER sideshift or rotate the spreader and NEVER
The green lights on the control panel will come ON when the derrick, extend or retract the boom while any of the twistlocks
twist locks are in the lock position. Make sure the indicator is still engaged in a corner casting of the container. Damage
flags for the twist locks are in the lock (orange flag) position. may occur to the spreader and the truck, or a container may
be accidentally moved causing it to fall.
WARNING
6. When the spreader has been correctly positioned, the
Make sure twist locks are engaged with the container
twistlocks will enter the corner castings and all four amber
(green light is ON and both orange indicator flags are
lights will be ON after the spreader is lowered on the con-
fully visible). If the green lights do not come ON, start the
tainer.
procedure again. If there is still a problem, contact
authorized service personnel. 7. If the load is being removed from a stack, first lift the load
from the stack, then slowly move away.
131
If the load is being removed from a stack, first lift the load to the center-line of the truck. Rotate the attachment until it
from the stack, then slowly move away. is perpendicular to the truck centerline. Retract the boom as
far as possible. Derrick the boom until the bottom of the con-
When the load is clear of the stack, retract the boom and use
tainer or trailer is 1 m (3.28 in.) higher than the operator seat.
the sideshift function to move the center of gravity of the load
to the center-line of the truck. Lower the load for traveling. 2. Adjust travel speed according circumstances. Travel
Always travel with the load perpendicular to the truck's cen- speed induces forces that affect truck stability when braking,
ter-line and as low as possible with the boom retracted as far steering and when driving over uneven surfaces. Reduce
as allowed by the LLMS. Lowering speed is controlled by the travel speed when approaching areas that may require sud-
position of the shift lever. Lower slowly and smoothly. Slowly den braking and/or steering. Limit truck speed to walking
return the shift lever to the Neutral position so the load is not speed when crossing uneven surfaces
dropped or the ReachStacker is not tipped over due to the
How to Deposit a Container
rapid stop of the load.
1. Put the container on an even surface or another container.
WARNING Be careful not to damage or move adjacent containers.
When rotating the container attachment with the over-
2. Lower the spreader until the amber lights come ON.
ride switch, use caution. The container can hit the boom
or operators compartment causing an accident, injury, CAUTION
or death. Do not hit the spreader on other containers or objects.
8. Move the container. See Traveling with a Container or The spreader can be damaged by hitting other items.
Trailer. 3. Unlock the twist locks. Make sure the red lights are OFF
Traveling with a Container or Trailer and the amber lights are ON. Check that the indicator flags
are in the disengaged position.
1. Move the container or trailer into the travel position. Use
the sideshift function to move the center of gravity of the load
132
NOTE: The audible alarm on the container handler control the operator must reduce speed and the load moment, so
box will sound when the twist lock switch is pushed to unlock that the ReachStacker will remain stable.
the twist locks. If for any reason the twist locks do not move
Avoid fast starts. Sudden movement can cause the Reach-
to the unlock position, the alarm will continue to sound.
Stacker to tip. People can be hurt or killed and material can
4. Lift the spreader from the container and move the Reach- be damaged.
Stacker.
Move forward slowly and approach the load carefully. Make
Load Handling sure that the ReachStacker is perpendicular to the trailer.
Raise the spreader to the proper height for engaging the
Before using the intermodal spreader, make sure all of the load.
controls operate as specified in Figure 9. The speed of the
boom is controlled by the position of the shift lever and the Keep the ReachStacker and spreader perpendicular to the
speed of the engine. The further the shift lever is moved from load.
the NEUTRAL position, the faster the speed of the hydraulic Always watch clearances around the whole length of the
function. trailer. Avoid hitting objects such as stacked material that can
Only handle loads within the rated capacity of the Reach- fall.
Stacker. Refer to the nameplate and the capacity chart Always keep the trailer as level as possible.
mounted on the ReachStacker. See Figure 19.
Always be careful of winds while handling trailers. Strong
Handle only stable loads. Do not lift or hit anything that can winds on raised containers can tip the ReachStacker. Do not
fall on the operator or a bystander. stack containers in winds above 45 km/h (28 mph).
Handle only balanced loads.
Check the condition of the driving surface. Rough terrain or
slopes can affect load handling. When such conditions exist,
133
How to Pick up a Trailer slightly, the green light will be ON when all four shoes of the
legs are engaged properly with the trailer.
CAUTION
Make sure that there is sufficient space at both sides of WARNING
the trailer to allow free movement of the legs. Make sure the legs are clamped to the trailer, amber
1. Retract the extension beams. Raise the attachment above lights on instrument panel and amber boom lights ON. If
the height of the trailer. Unfold (lower) the rear legs, closest the green lights do not come on, start the procedure
to the operator. Drive the ReachStacker towards the trailer again at step 3. If there is still a problem call for author-
until the rear legs are at a distance of about 10 cm (4 in.) to ized service personnel.
the trailer. Operate the side shift, rotate and boom functions 4. Raise the boom for traveling. Always travel with the load
to pre-position the rear legs for clamping the trailer, but do as low as possible. Lower slowly and smoothly. Slowly return
not yet clamp. the shift lever to the NEUTRAL position so that the load is
2. Lower the front legs. Check the lights on the boom. The not dropped or that the ReachStacker is not tipped over due
red light will be ON as the front legs are lowering. The red to the rapid stop of the load.
light will be OFF when the front legs are completely lowered. 5. Move the trailer. See Traveling with a Container or
Make sure the spreader is in the center, approximately, over Trailer.
the trailer. Use the sideshift and rotate functions to align the
spreader with the trailer. How to Deposit a Trailer
3. When the spreader is aligned with the trailer, engage the 1. Put the trailer on an even surface. Use caution not to dam-
legs to the trailer. The amber lights on the boom indicate the age or move adjacent trailers or containers.
legs are clamped to the trailer. Both amber lights will be 2. Lower the spreader to release the legs from the container.
ON when all four legs are in contact with the trailer. Lift The green lights will go OFF and the amber lights will remain
ON.
134
3. Open the legs from the container. Make sure the amber LLMS override
lights are OFF.
WARNING
CAUTION Never use the override function during normal opera-
Do not hit the spreader or legs on other containers or tion.
objects. The spreader can be damaged by hitting other
objects. The LLMS can be bypassed by using the override button and
operate the joystick at the same time.
4. Raise the front legs to the up position, red lights OFF and
move the ReachStacker. Emergency lowering
System overrides WARNING
Some generated interrupts can be manually overridden During the Emergency lowering procedure the LLMSI is
either pushing the override button on the twistlock module bypassed. If not handled correctly the truck can tip over.
(Override key switch must be ON for this override function to In case of an emergency (like an engine or hydraulic failure)
work) or pushing the attachment rotation override button on the load can be lowering by using the emergency lowering
the side console. function. Make sure the operator is seated, ignition is
Always be extra careful when using an override function. switched on, press the override button and retract the boom.
After the boom is retracted then derrick down until the load
is on the ground.
135
12 Degree Rotation override Twist Lock Override
WARNING WARNING
Use caution when rotating the spreader beyond the 12 Never use the Override Function when the container is
degree rotation limit. When rotating more than 12 not properly positioned on the ground or another con-
degrees the spreader, container or trailer can hit the tainer or personal injury may occur.
boom or operator's compartment causing an accident,
The container attachment needs to be seated on the con-
injury or death.
tainer before twist locks can be locked or unlocked. If the
ReachStacker. Push and hold the attachment rotation over- necessary seated signals cannot be obtained, the override
ride button while turning the joystick to rotate the container push button can be used to produce seated signals. Turn the
beyond the 12° limit. A light on the instrument panel and an override key switch into the "enable" position, push and hold
audible alarm will be ON when the override button is pushed. the override push button, and operate the extend and/or der-
ricking function to regain twist lock functionality.
Lift Interrupt Function override
Load Handling, Using a Sling
WARNING
Never lift a container when the lift interrupt is activated WARNING
(blue LED is ON). Never use override function when the Failure to follow these instructions can cause serious
container is not properly positioned on surface or other injury or death.
container.
1. Follow these instructions and the operation, inspections,
During locking or unlocking of the twist locks, lifting is disa- and maintenance instructions in Maintenance Schedule.
bled. During lift interrupt, the blue LED is ON. Lift interrupt
can be bypassed using the override button.
136
2. Before using a sling, inspect it for damage. Be sure it is in
good condition and has adequate capacity for load to be
handled.
3. Watch the clearance around the entire load.
4. Handle only loads within the capacity limits as shown on
the capacity chart mounted on the ReachStacker.
5. Load swing must be limited in all directions. Secure load
to the ReachStacker frame with ropes, chains, or fixtures.
See Figure 21 for location of tiedown. Additional tie points
can be added. Contact your authorized Hyster dealer. 1. TIE DOWN POINTS
Figure 21. Tie Down Points to Limit Load Swing
137
Docks Attachments
WARNING
WARNING Make sure the Nameplate is correct if an attachment has
Maintain a safe distance from the been installed.
edge of docks, ramps, platforms
and other similar working surfa-
ces. Watch the tail swing. Remem-
ber when traveling in the
FORWARD direction and the steer-
ing wheel is turned to move the
ReachStacker away from the edge
of the dock the rear will swing Attachments must be removed or installed by trained per-
toward the edge. This can cause sonnel only.
the ReachStacker to fall off the
dock.
Stopping
Stop the ReachStacker as gradually as possible. Hard brak-
WARNING ing and wheel sliding can cause the ReachStacker to tip for-
IF THE REACHSTACKER FALLS OFF THE DOCK, DO ward and damage the load or hurt someone.
NOT JUMP OFF! HOLD FIRMLY TO STEERING WHEEL,
BRACE YOUR FEET, AND LEAN FORWARD AND AWAY
FROM THE POINT OF IMPACT.
138
Parking CAUTION
NOTE: The parking brake, when in good condition and cor- The turbocharger can be severely damaged when
rectly adjusted, will hold a ReachStacker with a capacity load switching off a hot engine when the 3 to 5 minute idle
on a 15% grade [a slope that increases 1.5 in 10 m (1.5 in period is not performed.
10 ft)]. 4. Allow the turbocharger of the engine to cool down and to
NOTE: Do not park the ReachStacker so that it limits access obtain the lowest possible turbo speed before stopping the
to fire aisles, stairways, and fire equipment. engine. If engine coolant temperature is low to moderate,
keep the engine at lowest idle for 3 minutes before turning
The operator must never leave a ReachStacker in a condition the key switch to OFF. If engine temperature is high, keep
so that it can cause damage and injury. When parking the the engine at lowest idle for at least 5 minutes before turning
ReachStacker, do the following operations: the key switch to OFF.
1. Stop the ReachStacker and apply the parking brake. 5. If the ReachStacker must be left on an incline, put blocks
2. Raise the legs on an intermodal spreader. Retract the on the down hill side of the wheels so that the ReachStacker
spreader to the 20-foot position. Fully retract and lower the cannot move.
boom.
3. Put the shift lever for the transmission in NEUTRAL.
139
Maintenance
Maintenance
General WARNING
This section contains a Maintenance Schedule and the DO NOT make repairs or adjustments unless you have
instructions for maintenance and inspection. both authorization and training. Repairs and adjust-
ments that are not correct can make a dangerous oper-
The Maintenance Schedule has time intervals for inspec- ating condition.
tion, lubrication, and maintenance for your ReachStacker.
The service intervals are given in both operating hours recor- DO NOT operate a ReachStacker that needs repairs.
ded on the ReachStacker hourmeter, and in calendar time. Report the need for repairs immediately. If repair is nec-
Use the interval that occurs first. essary, put a DO NOT OPERATE tag in the operator's
area. Remove the key from the key switch.
Your dealer for Hyster ReachStacker has the equipment and
trained service personnel to do a complete program of WARNING
inspection, lubrication, and maintenance. A regular program Disposal of lubricants and fluids must meet local envi-
of inspection, lubrication, and maintenance will help your ronmental regulations.
ReachStacker give more efficient performance and operate
for a longer period of time. Serial Number Data
Some users have service personnel and equipment to do the The serial number for the ReachStacker is on the nameplate
inspection, lubrication, and maintenance shown in the Main- and also on the right-hand frame rail, near the counterweight.
tenance Schedule. Service Manuals are available from your The serial number indicates the design series, manufactur-
dealer for Hyster ReachStacker to help users who do their ing plant, and the year manufactured.
own maintenance.
140
Maintenance
How to Move a Disabled ReachStacker • Steering does not operate correctly.

• Tires are damaged.
WARNING
Manual release of the parking brake caliper will result in • Traction conditions are bad.
loss of brakes. • The ReachStacker must be towed on a slope.
The service brake system requires hydraulic pressure to If the engine cannot run, there is no power assist avail-
operate. The park brake will automatically apply when able for the steering and service brakes. This can make
hydraulic pressure drops. If there is no hydraulic pressure to the control of the ReachStacker difficult. Poor traction
release the parking brake, the parking brake caliper must be can cause the disabled ReachStacker or towing vehicle
manually released. Put blocks on both sides (front and back) to slide. Steep grades will increase the required brake
of the drive tires to prevent movement of the ReachStacker. effort.
The parking brake caliper is installed at the back of the dif-
ferential housing. To manually release the parking brake, Manual release of the parking brake caliper will result in
remove cotter pin from bolt in caliper. Tighten nut to com- loss of brakes.
press spring that applies brake. 1. Remove the drive shaft between the transmission and
drive axle.
How to Tow the ReachStacker
2. The towed ReachStacker must have an operator.
WARNING
3. Tow the ReachStacker slowly.
Do not tow the ReachStacker if a load is attached.
4. Tow the ReachStacker from lifting points of counterweight
Use extra caution when moving a ReachStacker if any of
attached to frame.
the following conditions exist:
• Brakes do not operate correctly.
141
Maintenance
5. If another ReachStacker is used to tow the disabled How to Raise the Drive Tires
ReachStacker, that ReachStacker must have an equal or
larger capacity than the disabled ReachStacker. 1. Apply the parking brake. Put blocks on both sides, front,
and back of the steering tires to prevent movement of the
6. Use a towing link made of steel that attaches to the lifting ReachStacker. See Figure 22.
points on the counterweights of both ReachStackers.
2. Fully lower and retract the boom.
How to Put a ReachStacker on Blocks
3. Use a hydraulic jack under the drive axle, where it supports
the frame. Leave room for blocks to be placed close to the
WARNING
drive tires. Make sure that the jack has a capacity of at least
The ReachStacker must be put on blocks for some types
45,000 kg (99,208 lb), equal to at least half the weight of the
of maintenance and repair. The surface must be solid,
ReachStacker. See the nameplate.
even, and level when the ReachStacker is put on blocks.
Make sure that any blocks used to support the Reach- 4. Put blocks under the drive axle, close to the drive tires.
Stacker are solid, one-piece units. Do not use compo- Lower the jack until the drive axle rests on the blocks.
nent lifting points on the boom or frame to lift the
ReachStacker.
142
Maintenance
How to Raise the Steer Tires 3. Place a hydraulic jack under center of steering axle to raise
the steering tires. Make sure that the jack has a capacity of
1. Apply the parking brake. Put blocks on both sides (front at least 2/3 of the total weight of the ReachStacker. See the
and rear) of the drive tires to prevent movement of the Nameplate.
ReachStacker. See Figure 22.
4. Put blocks with steel plates under both sides of the steer-
2. Put blocks between the steering axle and the frame. See ing axle to support the ReachStacker.
Figure 23.
WARNING
DO NOT put jack under the counterweight to raise the lift
truck.
143
Maintenance
1. DRIVE TIRES 2. STEERING TIRES
Figure 22. Put a ReachStacker on Blocks
144
Maintenance
How to Clean a ReachStacker
CAUTION
Your ReachStacker may be damaged if water or cleaning
agents come in contact with electrical components. DO
NOT directly spray any electrical components, espe-
cially connectors, switches, electro-hydraulic controls,
battery area, and dash display during the cleaning proc-
ess.
1. FRAME
2. WHEEL Portions of your ReachStacker may be washed with a non-
3. STEERING AXLE heated pressure washer. Steam cleaning is not recommen-
4. BLOCKS BETWEEN FRAME AND AXLE
5. SUPPORT BLOCKS
ded in most instances, as condensation may form in
6. STEERING AXLE PIVOT POINT electrical components causing damage or erratic behavior.
For cleaning guidelines and components to avoid, see the
Figure 23. Steering Axle Blocks Periodic Maintenance section of the Service Manual for
your ReachStacker.
145
Maintenance
Daily Inspections
NOTE: Portions reproduced by permission of Cummins Inc.
Figure 24. Maintenance Points (Sheet 1 of 3)
146
Maintenance
147
Maintenance
148
Maintenance
Table 22. Daily Inspections - Condition Check
Item No. Item Procedure

Warning and Safety Labels Check for presence and readability. Replace as
required. See Parts Manual.
Wheels, Tires and Tire Pressure Check condition and pressure. See Nameplate.
Wheel Nuts Re-torque nuts 8 hours after replacement of a wheel, or
8 hours after a nut could be turned at re-torquing.
Structural Weldment for Frame, Boom, and Spreader Perform a visual inspection of the welds. Notify qualified
maintenance personnel if abnormalities are detected.
33 Boom, Rotator, and Spreader Check condition. Repair as required.
21 Air Precleaner Dust Bowl Remove dust from bowl as required.
Hydraulic Tank Breathers Inspect restriction indicator. Replace element as
required. See Parts Manual.
Fuel, Oil, and Coolant Leaks Check for leaks. Repair as required.
22, 3 Radiator Sections for Engine Coolant, Charge Air Check and clean when needed. Check for leaks.
Cooler, Transmission and Hydraulic Oil
See Figure 24 for Item Nos.
149
Maintenance
Table 23. Daily Inspections − Fluid Level Check
Item Item Specification Procedure

No.
Windshield Washer Fluid Check level in reservoir. Add when needed.
19 Hydraulic System Oil John Deere
CAUTION
JDM-J20C
Additives in the hydraulic system oil may dam-
age the hydraulic system. Before using addi-
tives, contact your local HYSTER dealer.
Check level indicator with boom fully lowered and
retracted. Add oil if needed. Top off hydraulic oil
through hydraulic return filter.
16, 27 Engine Oil Level Maintain level halfway full range on dipstick when
cold.
Tier 3/Stage IIIA Engines 34 liter (9 gal) See Table 30.
Tier 4/Stage IIIB engines 22.8 liter (6 gal) See Table 30.
150
Maintenance
Table 24. Daily Inspections - Checks With the Engine Running
Item Item Procedure or Specification

No.
Seat Belt, Seat Rails and Steering Column Check condition and operation. Repair as required.
Windows and Mirrors Clean and adjust as required.
Horn, Gauges, Lights, Alarms, and Control System Visual or audible verification. Repair as required.
Signals from the LLMS Check operation. Repair as necessary.
Engine and Transmission Fault Codes Check fault code warning lights. The display should be free of fault
codes. Report any fault code.
Automatic Greasing System Display (Optional) Verify Green LED is ON. Report if Yellow and/or Red LED is ON.
Exhaust System High Temperature Light Make sure the exhaust pipe outlet is not directed at any surface
(Tier 4i only) or material that may become hazardous. If the area does not allow
high exhaust system temperatures, switch the Regeneration Con-
trol Switch to the ON position to postpone regeneration of the
diesel particulate filter. Perform a Stationary Regeneration Pro-
cedure at earliest convenience. See Exhaust System Regenera-
tion in the Operating Manual.
20 Engine Air Filter Replace main element when warning light is ON. Replace safety
element every third time main element is replaced.
151
Maintenance
Table 24. Daily Inspections - Checks With the Engine Running (Continued)

No.
Fuel Water Separator Drain water when warning light is ON.
24 Coolant Level Add coolant when warning light is ON. Report loss of coolant.
3174102 - Shell Rotella ELC
3116456 - Eurol Coolant XL-NM or equivalent
Hydraulic Filter Warning Light Replace high pressure hydraulic filter and the two hydraulic return
filters when the warning light is ON.
25 Fuel Level Avoid low fuel level. Refuel in time. See Table 30 for required fuel
specification. 830 liter (219 gal)
Control Levers, Switches, and Pedals Check operation as described in the Operating Manual.
Repair as required.
Parking and Service Brakes Check operation. Repair as required.
Steering System Check operation. Repair as necessary.
33 Boom, Rotator, and Spreader Check operation. Repair as necessary. Check operation. Repair
as necessary.
Signals from the Spreader Control System Check operation. Repair as necessary.
152
Maintenance
Table 24. Daily Inspections - Checks With the Engine Running (Continued)

No.
14 Transmission Check operation. Repair as necessary.
Operator Presence System Check operation. Repair as necessary.
29 Transmission Oil Level Add if needed. Dexron® III
153
Maintenance
Table 25. First Inspection After First 100 Hours of Operation
Item Item Procedure Quantity Specification

No.
8 Transmission Oil Filter Change 2 See Parts Manual.
High Pressure Brake Cooling Change 1 See Parts Manual.
Filter
154
Maintenance
Table 26. First Inspection After First 250 Hours of Operation
Item Item Procedure Quantity Specification

No.
6 Bearing Pre-torque in Steer Check Torque See Steering Axle 1600 SRM 1114 for proce-
Wheel Hubs dure.
6 Oil in Steer Wheel Hubs Change 4 liter MIL-L-2105D
(1.06 gal) API-GL-5
each SAE 90.
Bearing Pre-torque in Drive Check Torque. See Service Manual.
Wheel Hubs
Differential Oil Change. 74 liter API-GL-5
(19.5 gal) MIL-L-2105D
SAE 90
Also clean
magnetic plugs.
Oil in Drive Wheel Hubs Change. 11 liter API-GL-5
(2.9 gal) each MIL-L-2105D
side. SAE 90
Also clean
magnetic plugs.
155
Maintenance
Table 27. Periodic Maintenance Schedule − Inspect and Adjust
Item Item Interval Procedure

No.
Warning and Safety Labels 250 hr/3 mo Check for presence and readability. Replace as required.
See Parts Manual.
Wheels, Tires, and Tire Pressure 250 hr/3 mo Check condition and pressure. See nameplate.
Wheel Nuts, Drive Wheels 250 hr/3 mo Check torque:
Kessler 350 to 400 N•m (258 to 295 lbf ft)
Axle Tech 405 to 440 N•m (300 to 325 lbf ft)
Wheel Nuts, Steer Wheels 250 hr/3 mo Check torque. 350 to 400 N•m (258 to 295 lbf ft)
18 Hydraulic Tank Breathers 250 hr/3 mo Inspect restriction indicator. Replace elements when needed.
See Parts Manual.
21 Air Precleaner 250 hr/3 mo Remove dust from dust bowl as required.
Fuel, Oil, and Coolant Leaks 250 hr/3 mo Check for leaks. Repair as required.
Engine Air Intake and 250 hr/3 mo Check for wear points, damage, leaks, loose clamps or loose
Charge Air Piping connections. Repair as required.
Coolant Hoses 250 hr/3 mo Inspect for cracks, cuts and collapsing. Replace as required.
See Parts Manual.
156
Maintenance
Table 27. Periodic Maintenance Schedule − Inspect and Adjust (Continued)

No.
26 Drive Belts 250 hr/3 mo Check tension and condition. Replace as required. See Parts
Manual.
Engine Compartment 250 hr/3 mo Remove combustible materials. Remove all foreign materi-
als.
3 Radiator sections for Engine Coolant, 250 hr/3 mo Check and clean when necessary. Check hoses and tube
Charge Air Cooler, Transmission and connections for leaks.
Hydraulic Oil
11, 12 Drive Axle and Differential 250 hr/3 mo Check oil levels. Add oil if needed. Clean magnetic plugs.
API-GL-5, MIL-L-2105D, SAE 90.
6 Oil in Steer Wheel Hubs 250 hr/3 mo Check oil levels. Add oil if necessary. Clean magnetic plugs.
MIL-L-2105D
API-GL-5
SAE 90.
Windshield Washer Fluid 250 hr/3 mo Check level in reservoir. Add when needed.
17 Hydraulic System Oil 250 hr/3 mo Check level indicator. Add hydraulic oil if needed through the
hydraulic return filter.
JDM-J20C.
157
Maintenance

No.
24 Coolant Level 250 hr/3 mo Inspect level at the expansion tank. If level is below "MIN"
mark, inspect for leaks, repair as needed, and add coolant to
the "MAX" mark
3174102 - Shell Rotella ELC
3116456 - Eurol Coolant XL-NM or equivalent
16 Engine Oil Level 250 hr/3 mo Maintain level halfway full range on dipstick when cold.
API CH-4/SJ
SAE15W-40
−18 °C (0 °F).
15 Fuel Filter/Water Separator 250 hr/3 mo Drain water until clean fuel flows from the filter.
29 Transmission Oil Level 250 hr/3 mo Add oil if needed. DEXRON III.
Seat Belt, Seat Rails, and Steering 250 hr/3 mo Check condition and operation. Repair as required.
Column
Operator Presence System 250 hr/3 mo Check operation. Repair as required.
158
Maintenance

No.
Automatic Greasing System 250 hr/3 mo Check proper functioning of the Central Greasing System.
Add grease if reservoir is empty or almost empty.
Multipurpose grease.
EP2, EP3. Without MoS2. NLGI Grade 2.
Structural Weldment for Frame, Boom, 500 hr/3 mo Perform a visual inspection of the welds. Report any crack
and Spreader found to the Hyster Company Service Group.
33 Boom Wear Pads 500 hr/6 mo Replace wear pads if thickness is 18 mm (0.71 in.) or less.
Make sure that retaining hardware is tightened to 165 N•m
(121.7 lbf ft).
33 Boom Side Wear Pads 500 hr/6 mo Check Adjustment. Replace pads when worn.
Cab Air Filter 500 hr/6 mo Check element. Replace element when needed. See Parts
Manual.
10 Parking Brake and Service Brakes 1000 hr/6 mo Check condition and operation. Repair as required.
24 Coolant Quality 1000 hr/6 mo 40 liter; Check acidity and freezing point. Replace factory-
filled coolant if pH level is lower than 7.7.
26 liter.
159
Maintenance

No.
28 Brake System Accumulator 2000 hr/12 mo Make sure pre-charge pressure at gauge is 10.35 MPa
(1501 psi).
Transmission Clutch Calibration 2000 hr/12 mo Perform clutch calibration.
Inching Pedal Sensor Calibration 2000 hr/12 mo Check calibration and adjust as required.
6 Steer Wheel Hub Bearings 2500 hr/12 mo Check pre-torque. See the section Steering Axle 1600 SRM
1114.
Engine Cleaning 3000 hr/12 mo Clean engine if needed.
Engine and Transmission Mounts 3000 hr/12 mo Check for aging and deterioration. Replace if necessary. See
Parts Manual.
Turbo Charger 3000 hr/12 mo Tighten clamps and hardware. Establish correct sealing.
Check progress of brake lining wear. 3000 hr/12 mo Measure progress of brake lining wear. See Service Man-
ual.
27 Engine Valve Adjustment 5000 hr Check valve clearance. See engine identification plate for
adjustment values.
26 Belt and Tensioner 6000 hr/24 mo Check tension and belt condition. Replace as required. See
Parts Manual.
160
Maintenance

No.
26 Belt Hubs, Idler Pulley 6000 hr/24 mo Inspect condition and proper rotation. Replace as required.
See Parts Manual.
26 Vibration Damper 6000 hr/24 mo Check for fluid loss and deformation. Replace if needed. See
Parts Manual.
161
Maintenance
Table 28. Periodic Maintenance Schedule - Lubricate
Item Item Interval Quantity Specification

No.
* Tracks for Boom Wear Pads 500 hr/3 mo 10 Tracks Multipurpose grease.
EP2, EP3. Without MoS2.
Automatic Greasing System 500 hr As Required Add grease to maximum level in each
(Optional) reservoir.
Multipurpose grease.
NLGI-2. Without MoS2.
31* Boom Pivot to Attachment 500 hr/3 mo 2 Fittings Multipurpose grease.
32* Dampening Cylinder Pivot 500 hr/3 mo 4 Fittings Multipurpose grease.
Points EP2, EP3. Without MoS2.
34* Boom Pivot to Frame 500 hr/3 mo 2 Fittings Multipurpose grease.
5* Steering Axle Tie Rod Pins 500 hr/3 mo 4 Fittings MoS2 grease.
7* King Pins 500 hr/3 mo 4 Fittings Multipurpose grease.
NOTE: The items marked with '*' do not require manual greasing when the truck is equipped with the Automatic Greasing
System for truck and attachment.
162
Maintenance
Table 28. Periodic Maintenance Schedule - Lubricate (Continued)

No.
4* Steering Axle Pivot 500 hr/3 mo 1 Fitting Multipurpose grease.
Cab Door Hinges 1000 hr/6 mo 4 Fittings Multipurpose grease.
13 Drive Shaft 2000 hr/12 mo 3 Fittings Multipurpose grease.
163
Maintenance
Table 29. Periodic Maintenance Schedule - Change

No.
16 Engine Oil 500 hr/6 mo
Tier 3/Stage IIIA Engines 34 liter (9 gal) See Table 30.
Tier 4i/Stage IIIB Engines 22.8 liter (6 gal) See Table 30.
2 Engine Oil Filter 500 hr/6 mo 1 See Parts Manual.
15 Fuel Filter/Water Separator 500 hr/6 mo 1 See Parts Manual.
High Pressure Brake Cool- 1000 hr/6 mo 1 See Parts Manual. Replace at hydraulic oil
ing Filter change and after major hydraulic system repair.
8 Transmission Oil Filter 1000 hr/6 mo 2 See Parts Manual.
29 Transmission Oil 1000 hr/6 mo 62 liter (16 gal) Dexron® III.
Engine Crankcase Breather 2500 hr/12 mo 1 See Parts Manual.
Filter
6 Oil in Steer Wheel Hubs 2500 hr/12 mo 4 liter (1 gal) MIL-L-2105D
each side. API-GL-5
SAE 80W-90.
Differential Oil 2500 hr/12 mo 74 liter (19.5 gal) API-GL-5, MIL-L-2105D, SAE 90. Also clean
magnetic plugs.
164
Maintenance
Table 29. Periodic Maintenance Schedule - Change (Continued)

No.
Oil in Drive Wheel Hubs 2500 hr/12 mo 11 liter API-GL-5, MIL-L-2105D, SAE 90. Also clean
(2.9 gal)each magnetic plugs.
side.
1 Engine Coolant Filter for 3000 hr/36 mo 1 See Parts Manual.
QSM11 Engine Only
19 Hydraulic System Oil 3000 hr/36 mo 605 liter
CAUTION
(160 gal)
Additives in the hydraulic system oil may
damage the hydraulic system. Before using
additives, contact your local Hyster dealer.
John Deere JDM-J20C. Replace oil at 3000
hours, or take oil sample at 3000, 4000 and 5000
hours and follow instructions of the Laboratory
report.
17 Hydraulic Return Oil Filter 3000 hr/36 mo 2 See Parts Manual. Replace at hydraulic oil
change.
9 Brake Return Line Filter 3000 hr/36 mo 1 See Parts Manual. Replace at hydraulic oil
change.
165
Maintenance
Table 29. Periodic Maintenance Schedule - Change (Continued)

No.
Automatic Greasing System 5000 hr 1 Replace or clean filter at filter coupling.
Filter (Optional) See Parts Manual.
Diesel Particulate Filter 5000 hr 1 See Parts Manual.
(Tier 4i only)
Air Conditioning System 5000 hr/36 mo Contact certified AC specialist for replacing dryer,
lubricant, and refrigerant. R134A 1300
±50 grams (45.86 ±1.76 oz).
19 Hydraulic System 10,000 hr 1 See Parts Manual.
Suction Filter Also replace after major hydraulic system repair.
High Pressure Main Manifold 10,000 hr/60 mo 1 See Parts Manual. Also replace after major
Filter hydraulic system repair.
166
Maintenance
Table 30. Approved Fuels and Engine Oils
Emission WWFC Sulfur ASTM Sulfur Engine Quantity
Legislation Diesel Fuel Content D975 Content Oil
Grade No. 2-D
Tier 4i Category 4 <10 mg/kg S15 <15 mg/kg ACEA E9 22.8 liter
Stage IIIB Engines API CJ-4 (24 qt)
Tier 3 Category 4 <10 mg/kg S5 <15 mg/kg ACEA E7 or E9 34 liter
Stage IIIA Engines API CI-4 or CJ-4 (36 qt)
Category 2 <500 mg/kg S500 <500 mg/kg ACEA E7
API CI-4
Non-Compliance Category 1 <5000 mg/kg S5000 <5000 mg/kg ACEA E7 34 liter
API CI-4 (see NOTE 5 and NOTE 6) (36 qt)
NOTE: 1. To comply with emission legislation, sulfur content in the applied diesel fuel must be limited. See column WWFC Diesel Fuel
Category.
NOTE: 2. Sulfur content in diesel fuel determines the required engine oil specification.
NOTE: 3. Maintain engine oil level halfway full range on dipstick when cold.
NOTE: 4. Diesel Category 1 is not allowed in countries with Tier 3/Stage IIIA or more stringent emission legislation.
NOTE: 5. When using Diesel Category 1, the factory-filled CJ-4 engine oil must be replaced at initial 250 hours by API CI-4 specification
oil.
NOTE: 6. When using Diesel Category 1, engine oil specification API CI-4 must be used to allow 500-hour oil change intervals.
NOTE: 7. Bio diesel fuel may be blended with mineral diesel fuel, provided the bio diesel content does not exceed 5 percent of total volume.
167
Maintenance
Ambient Temperature Viscosity

−15 °C (5 °F) and above 15W-40
−20 °C (−4 °F) to 20 °C (68 °F) 10W-30
Below 0 °C (32 °F) 0W-30
NOTE: Ambient temperatures determine the viscosity of the oil to be selected.
168
Maintenance
Container Attachment Maintenance
Figure 25. Extendable Container Attachment Maintenance Points
169
Maintenance
Figure 26. Intermodal Container Attachment Maintenance Points
170
Maintenance
Table 31. Initial 100-Hour Inspection (See Figure 25 and Figure 26)
Item Item Specification Quantity Procedure

No.
8 Oil in Rotator Transmission MIL-L-2105D 5.2 liter Drain and fill with gear oil.
API-GL-5 (1.4 gal) SAE 80W-90 API GL5
SAE 90.
Table 32. Inspect and Adjust (See Figure 25 and Figure 26)

No.
Attachment 250 hr Check condition and operation. Check for
damage, cracks and distortion. Check for
leakage of hydraulic components. Repair
as required.
6 Signals from the Spreader Control System 250 hr Check for correct operation. Repair as
required.
1 Twist Locks 250 hr Check for wear and possible damage of
the twist lock and twist lock sleeve.
Replace as required.
171
Maintenance
Table 32. Inspect and Adjust (See Figure 25 and Figure 26) (Continued)

No.
8 Oil Level in Rotator Transmission 250 hr Check Oil Levels.
API-GL-5
MIL-L-2105D
SAE 90
5.2 liter (1.4 gal)
3 Attachment Wear Pads 500 hr Replace wear pads if thickness is 18 mm
(0.71 in.) or less. Make sure that retaining
hardware is torqued to 63 N•m
(46.47 lbf ft).
172
Maintenance
Table 33. Lubricate (See Figure 25 and Figure 26)
Item Item Interval Quantity Procedure

No.
2* Rotator Ring Gear 100 hr Dental Surface Gear Lubricant with adhesive and
EP2 additive.
2* Ring Gear Bearing 100 hr 4 Fittings Multipurpose grease.
9* Leg Folding Group 100 hr 10 Fittings Multipurpose grease.
(ELME model 857 only) EP2, EP3. Without MoS2.
10* Foot at Bottom of Legs 100 hr 8 Fittings Multipurpose grease.
(ELME model 857 only) EP2, EP3. Without MoS2.
1* Twist Locks 500 hr 8 fittings Multipurpose grease.
3* Bearing Pad Tracks for Extension 500 hr 24 Tracks Multipurpose grease.
Beams EP2, EP3. Without MoS2.
4* Sideshift Slider Pads 500 hr 4 Tracks Multipurpose grease.
5* Sideshift Cylinder Bearings 500 hr 4 fittings Multipurpose grease.
173
Maintenance
Table 33. Lubricate (See Figure 25 and Figure 26) (Continued)

No.
5 Powered Pile Slope Cylinders 500 hr 2 fittings each cyl- Multipurpose grease.
inder EP2, EP3. Without MoS2.
* Stop Cylinders 500 hr 1 Fitting Multipurpose grease.
Each Cylinder EP2, EP3. Without MoS2.
Locking Plate for Stop Cylinder 500 hr MoS2 grease.
Extension Cylinder Support Pad 1000 hr 2 Tracks in Multipurpose grease.
Each Beam EP2, EP3. Without MoS2.
Table 34. Change (See Figure 25 and Figure 26)

No.
8 Oil in Rotator Transmission 2000 hr 5.2 liter MIL-L-2105D
(1.4 gal) API-GL-5 SAE 90.
1 Twist Locks 5000 hr 4 See Parts Manual.
174
Maintenance
Maintenance Procedures Every 8 Hours or Daily

How to Make Checks With the Engine Stopped Check that all safety labels are installed in the correct loca-
tions on the lift truck. See the Parts Manual for the correct
WARNING location of the safety labels.
Do not operate a lift truck that needs repairs. Report the If new labels must be installed, use the following procedures:
need for repairs immediately. If repair is necessary, put
a DO NOT OPERATE tag in the operator's area. Remove WARNING
the key from the key switch. Cleaning solvents can be flammable and toxic and can
Put the lift truck on a level surface. Fully lower and retract the cause skin irritation. When using cleaning solvents,
boom, stop the engine, and apply the parking brake. Open always follow the recommendations of the manufac-
the hood and check for leaks and conditions that are not nor- turer.
mal. Clean any oil or fuel spills. Make sure all surfaces are 1. Verify the surface is dry and has no oil or grease. Do not
free of oils, lubricants, fuel, and organic dust or fibers (paper, use solvent on new paint. Clean the surface of old paint with
wood, cotton, wool, agricultural grass/grain, etc.). a cleaning solvent.
Warning and Safety Labels 2. Remove the paper from the back of the label. Do not touch
the adhesive surface.
WARNING
3. Carefully hold the label in the correct position above the
Safety labels are installed on the lift truck to give infor-
surface. The label cannot be moved after it touches the sur-
mation about operation and possible hazards. It is
face. Put the label on the surface. Make sure that all air is
important that all safety labels are installed on the lift
removed from under the label and the corners and edges are
truck and can be read.
tight.
175
Maintenance
Wheels, Tires, and Tire Pressure Check the tires for damage. See Figure 27. Inspect the tread
and remove any objects that will cause damage. Check for
WARNING bent or damaged rims. Check for loose or missing parts.
Air pressure in pneumatic tires can cause tire and wheel Remove any wire, straps, or other material wrapped around
parts to explode. The explosion of wheel parts can cause the axle.
serious injury or death.
Remove all of the air from the tires before the tires are
removed from the lift truck.
If the air pressure is less than 80% of the correct air
pressure, the tire must be removed before air is added.
Put the tire in a safety cage when adding air pressure to
the tire. Follow the procedures described in LINE TO
ADDING AIR PRESSURE TO TIRE.
When air is added to the tires, use a remote air chuck.
The person adding air must stand to the side of the
safety cage and not in front of it.
Keep the tires at the correct air pressure. See the Nameplate. 1. CHECK TIRE PRESSURE
Check the air pressure with a gauge when the tires are cold. 2. CHECK FOR DAMAGE
If it is necessary to add air to a tire that is warm, check one Figure 27. Tire Check
of the other tires on the same axle and add air to the tire that
has low pressure so that the air pressures are equal. The air
pressure of warm tires must always be equal to or greater
than the specification for air pressure for cold tires.
176
Maintenance
Wheel Nuts Air Precleaner Dust Bowl

Clean the precleaner for the air filter as necessary. Remove
CAUTION
the cover for the precleaner, then remove the dirt from the
Check all wheel nuts after 2 to 5 hours of operation:
bowl. Install the bowl and cover. See Figure 28.
when new lift trucks begin operation and on all lift trucks
when the wheels have been removed and installed.
Tighten the nuts as shown in Figure 39. When the nuts
stay tight for eight hours, the interval for checking the
torque can be extended to 500 hours.
Too little torque of the wheel nuts can cause the wheel
to slip on the hub and cause damage. Too much nut tor-
que can damage studs, spacer bands, and wheels.
Make sure the wheel nuts are tight. Tighten the wheel nuts
as shown in Figure 39.
Boom, Rotator, and Spreader
1. Inspect the boom sections for cracks and wear.
2. Inspect the spreader sections for cracks and wear.
3. Tighten any nuts or bolts that are loose. Replace any dam-
aged or broken parts.
177
Maintenance
Hydraulic Tank Breathers

NOTE: Never remove the safety stand pipe to avoid dirt from
entering the hydraulic system.
NOTE: Correct maintenance is very important to avoid
unnecessary dirt from entering the hydraulic system. The dirt
will not be filtered by the return line filters and may directly
enter the gear pumps.
There are two hydraulic tank breathers placed on the
hydraulic tank. Only one hydraulic tank breather is equipped
with an indicator. When replacement of the filter is necessary
always replace filters for both hydraulic tank breathers.
NOTE: First press the yellow button on the indicator to
release pressure to replace the filter.
Remove the cap from the hydraulic tank breather. Remove
the filter and clean the inside of the hydraulic tank breather
with solvent. Install the new filter and cap.
1. PRECLEANER 3. VACUUM SWITCH
2. AIR FILTER
Figure 28. Air Filter Tier 3
178
Maintenance
Radiator Sections for Engine Coolant, Charge Inspect the radiator sections for leakage and fin damage.
Air Cooler, Transmission and Hydraulic Oil Replace damaged sections and hoses.
WARNING Windshield Washer Fluid

Compressed air can move particles so that they cause The reservoir is located at the left rear corner of the opera-
injury to the user or to other personnel. Make sure that tor's cab. Check the level in the reservoir through the three
the path of the compressed air is away from all person- holes in the operator's cab frame. Add fluid, if needed, by
nel. Wear protective goggles or a face shield to prevent using the fill opening located outside the operator's cab.
injury to the eyes.
Clean the radiator with compressed air or water as needed.
Be careful not to bend the radiator fins.
179
Maintenance
Hydraulic System Oil Check the hydraulic oil level when the boom is fully lowered
and retracted, and the engine is stopped. Add hydraulic oil
WARNING only as needed. Hydraulic oil level is correct when it is in the
At operating temperature, the hydraulic oil is HOT. Do green area. Add hydraulic oil if the oil level is in the red area.
not permit the oil to contact the skin and cause a burn. If hydraulic oil level is in the yellow area and the oil is cold,
there is a risk that during operation hydraulic oil will leak from
CAUTION the breather. See Figure 29.
Do not permit dirt to enter the hydraulic system when the Check the hydraulic system for leaks and damaged or loose
oil level is checked or the filter is changed. components.
Never operate the hydraulic pumps without oil in the
hydraulic system. The operation of the hydraulic pumps
without oil will damage the pumps.
Only use the oil specified in the Maintenance Schedule.
CAUTION
Additives in the hydraulic system oil may damage the
hydraulic system. Before using additives, contact your
local HYSTER dealer.
180
Maintenance
1. HYDRAULIC RETURN LINE FILTERS

2. BREATHERS
3. COVER
4. LEVEL INDICATOR
5. INSPECTION COVER
6. SUCTION FILTERS
7. HYDRAULIC TANK
Figure 29. Hydraulic Tank and Filters
181
Maintenance
Engine Oil Level After the engine has stopped, wait one minute before check-
ing the oil level. Keep the oil at the correct level as indicated
WARNING on the dipstick. See Figure 30 or Figure 31. Use the correct
Long-term exposure to used engine oil can cause skin oil as shown in Table 30.
irritation or cancer. Use caution when checking or add-
ing oil to the engine. If oil comes in contact with skin,
wash with detergent and water.
182
Maintenance
A. LEFT HAND VIEW B. RIGHT HAND VIEW

1. OIL DIPSTICK 7. ELECTRONIC CONTROL MODULE (ECM)
2. ENGINE OIL FILL CAP 8. ALTERNATIVE ENGINE OIL FILL
3. FUEL FILTER 9. STARTER
4. OIL FILTER 10. HYDRAULIC PUMP
5. COOLANT FILTER 11. TRANSMISSION DIPSTICK
6. ENGINE OIL DRAIN PLUG
Figure 30. Engine Maintenance Points Tier 3/Stage IIIA
183
Maintenance
A. LEFT HAND VIEW B. RIGHT HAND VIEW

1. OIL DIPSTICK 6. ENGINE OIL DRAIN PLUGS
2. ENGINE OIL FILL CAP 7. ELECTRONIC CONTROL MODULE (ECM)
3. FUEL FILTER 8. HYDRAULIC PUMPS
4. OIL FILTER 9. STARTER
5. EXHAUST GAS RECIRCULATION (EGR) 10. TRANSMISSION DIPSTICK
Figure 31. Engine Maintenance Points Tier 4/Stage IIIB
184
Maintenance
How to Make Checks With Engine Running Make sure that the area around the lift truck is clear before
starting the engine or making any operational checks. Be
WARNING careful when making the checks. If the lift truck is stationary
Exhaust from internal combustion engines contains car- during a check, apply the parking brake and put the trans-
bon monoxide and other harmful chemicals. Carbon mission in NEUTRAL. Make the checks carefully.
monoxide is a colorless, odorless poison and can cause Seat Belt, Seat Rails, and Steering Column
unconsciousness or death without warning. Long term
exposure to exhaust or chemicals in the exhaust can The seat belt, seat, and mounting are all part of the operator
cause cancer, birth defects, and other reproductive restraint system. Each item must be checked to make sure
harm. it is attached securely, functions correctly, and is in good
condition. See Figure 32.
Avoid exposure to engine exhaust:
Make sure the seat rails are not loose. The seat rails must
• Do not use diesel engines indoors where soot can
lock securely in position, but move freely when unlocked. The
accumulate.
seat rails must be securely attached to the mounting surface.
• If engines are operated in confined spaces, maintain
The end of the seat belt must fasten correctly in the latch.
adequate ventilation or vent exhaust to the outside.
Make sure the seat belt pulls from the retractor assembly and
Do not exceed applicable air contaminant limits.
retracts smoothly. The seat belt must be in good condition.
• Follow the inspection and maintenance schedule and A seat belt that is damaged or torn will not give protection
procedures in this manual. Do not alter exhaust, igni- when it is needed. If the seat belt cannot be pulled from the
tion, or fuel systems. retractor assembly, replace the seat belt assembly.
FASTEN YOUR SEAT BELT! The seat belt is installed to
help the operator stay on the truck if the lift truck tips
over. IT CAN ONLY HELP IF IT IS FASTENED.
185
Maintenance
Steering Column Latch

Make sure the latch for the steering column operates cor-
rectly. The latch must NOT allow the column to move unless
the latch is released.
Gauges, Lights, Horn, Fuses, and Relays
Start the engine. Check the gauges and lights for correct
operation as described in the Operating Manual. Check the
operation of the horn and reverse warning alarm. The fuse
panel is located behind the door at the left side of the instru-
ment panel. The relays are located left of the fuse panel. See
Figure 33 and Figure 35.
The battery compartment contain the fuses for the alternator,
engine ECM, and transmission controller. See Figure 34.
1. SEAT BELT RETRACTOR

2. SEAT BELT LATCH
3. SEAT RAIL
Figure 32. Safety Belt and Seat Rails
186
Maintenance
Legend for Figure 33
1. FUSE PANEL 1
• IGNITION/ENGINE START, 30A
• ECM IGNITION, 5A
• OPS SYSTEM, 5A
• TRANSMISSION, 7.5A
• TRANSMISSION B+, 7.5A
• HYDRAULIC CONTROLLERS, 30A
• ATTACHMENT CONTROLS, 15A
• PARK BRAKE SOLENOID, 5A
• INSTRUMENTATION, 10A
• ALTERNATOR, 5A
2. FUSE PANEL 2
• FLOOD LIGHTS, 30A
• STROBE LIGHTS B+, 5A
• BRAKE LIGHTS, 10A
• FRONT DRIVE LIGHTS, 15A
• INTERIOR LIGHTS, 5A
• MAST/ATTACHMENT LIGHTS, 15A
• DIRECTION INDICATORS, 10A
• SIDE/TAIL LIGHTS, 10A
• REAR DRIVE LIGHTS, 10A
•REVERSE LIGHTS/ALARM AND STROBE, 10A
3. FUSE PANEL 3
• FRONT SCREEN WASH/WIPE, 10A
• ROOF SCREEN WASH/WIPE, 10A
• REAR SCREEN WASH/WIPE, 10A
• HORN, 10A
Figure 33. Fuse Panel • CAB TILT POWER ASSIST, 20A
• ENGINE COMPARTMENT LIGHT, 10A
187
Maintenance
• SEAT SUSPENSION COMPRESSOR, 15A
• HEATER/AC/VENTILATION, 25A
• AC FAN 1, 15A
• AC FAN 2, 15A
4. FUSE PANEL 4
• POWER SOCKET 12V,-10A
• RADIO/CB/INTERCOM, 10A
• 12V CONVERTER ACCESSORIES, 10A
• HAZARD FLASHERS, 10A
• OPEN
• 12V RELAY, 3A
• AUTOMATIC LUBRICATION (OPT.), 10A
• OPEN
• ACCESSORY SOCKET 24V B+, 15A
• ACCESSORY SOCKET 24V IGN, 5A
5. ECO/ELO SWITCH
6. HYDRAULIC SERVICE SWITCH
7. TRANSMISSION CALIBRATION SWITCH
8. RELAY SEE FIGURE 22
9. DIAGNOSTIC PLUG
Figure 34. Sealed Disconnect and Fuse Compartment
188
Maintenance
Legend for Figure 34
1. SLIDING CAB SWITCH
2. BATTERY DISCONNECT SWITCH
3. APC200
4. GRID HEATER RELAY
5. ALTERNATOR FUSE (1 @ 24V-100A)
6. CAB FUSE (1 @ 24V-125A)
7. GRID HEATER FUSE (1 @ 24V-125A)
8. APC200 FUSE (1 @ 24V-7.5A)
9. ECM BATTER (1 @ 24V-30A)
Figure 35. Relays
189
Maintenance
Windows and Mirrors High Exhaust System Temperature Light

Make sure the windows of the cab are clean, and the window Make sure the exhaust pipe outlet is not directed at any sur-
wipers operate correctly. Have the mirrors correctly adjusted. face or material that may become hazardous. If the area does
not allow high exhaust system temperatures, switch the
Fault Codes Regeneration Control Switch to the ON position to postpone
If the engine, transmission or hydraulic controller detects a regeneration of the diesel particulate filter. Perform a Sta-
fault, the hourmeter/fault code display will show a fault code tionary Regeneration Procedure at earliest convenience.
instead of the engine hours. The instrument cluster logs the See section on Exhaust System Regeneration (Tier 4i/
fault code. If a fault appears, report the fault immediately. DO Stage IIIB Engines Only) in this manual.
NOT operate the lift truck until the fault is corrected. The Engine Air Filter
central warning lights will be illuminated when there is a fault
condition. When all faults have been cleared or repaired, the NOTE: Clean the precleaner for the air filter as necessary.
hourmeter/fault code display will show engine running hours Remove the cover for the precleaner, then remove the dirt
again. from the bowl. Install the bowl and cover. See Figure 28.
See Cummins Engine Fault Code Guide 600 SRM 1101 NOTE: When cleaning of the air filter container is not per-
for engine fault codes. formed, during maintenance and/or when replacing the filter,
dirt will gradually build up in the filter housing. This may
See APC200 Fault Code Guide 1300 SRM 1435 for trans-
cause, non-proper functioning of the filter unit. In some
mission fault codes.
cases, when being installed, the filter element can only be
See Hydraulic Control System 1900 SRM 1534 for forced into place. Over time, this may cause the filter housing
hydraulic system fault codes. to crack. Dirt in the unfiltered air can damage the engine.
Check the air restriction indicator with the engine operating.
Replace the main element when indicator light is ON. The
190
Maintenance
safety element should be changed every third time the main Add coolant when the Coolant Level Warning Light is ON.
element is replaced. Before opening the radiator cap, wait until the cooling system
is cooled down. If coolant is added, use an OAT (Organic
To inspect the element, put a bright light inside and look for
Acid Technology) type coolant. Add coolant until coolant
holes or other damage. If the element is damaged, replace it
level just touches the tube in the filler neck of the overflow
with a new element. Clean the inside of the canister with a
tank. Report the date and quantity of coolant that has been
damp cloth when changing filters.
added. Check the cooling system for leaks if more than 1 liter
Coolant Level (0.26 gal) must be added per 1000 running hours.
High Pressure Brake Cooling Filter
WARNING
DO NOT remove the radiator cap when the engine is hot. Replace the high pressure brake cooling filter when the
When the radiator cap is removed from the expansion warning light is ON.
tank, the pressure is released from the system. If the
1. Lower the mast, shut down the engine, and apply the
system is hot, the steam and boiling coolant can cause
parking brake.
burns.
2. Apply the brake pedal a minimum of ten times to relieve
CAUTION the hydraulic pressure.
DO NOT operate the engine when the coolant tempera-
3. Use a wrench to loosen the bowl that holds the filter car-
ture gauge needle is in the red area. Engine damage can
tridge. See Figure 36.
occur.
4. Remove and replace the filter cartridge and reinstall the
CAUTION bowl. Torque to 20 N•m (177.02 lbf in).
Additives in the coolant may damage the cooling sys-
tem. Before using additives, contact your local Hyster
dealer.
191
Maintenance
A. REAR OF TRUCK
1. HYDRAULIC HIGH PRESSURE FILTER 3. CLOGGING INDICATOR
2. FILTER ELEMENT 4. O-RING BOWL
Figure 36. Hydraulic High Pressure Filter
192
Maintenance
Engine Oil Pressure NEVER fill the fuel tank near an open flame or near
equipment that can create sparks. Never check the fuel
There is an oil temperature warning light, oil temperature level or check for leaks with an open flame.
gauge and an oil pressure gauge for the engine. The red light
is ON when the key switch is in the START position and must When adding fuel, keep the funnel or fuel nozzle in con-
go OFF when the engine is running. During normal operation tact with the metal of the fuel tank to reduce the possi-
the needle of the temperature gauge will be in the green area, bility of static electric sparks. Clean any spilled fuel.
the needle of the pressure gauge will be approximately in the Breathing fuel vapor may cause nausea, unconscious-
middle of the scale. ness, or death. Long-term exposure to fuel vapors may
cause liver or kidney damage and cancer. Avoid breath-
Fuel Level
ing vapor.
NOTE: Read the Fuel Level Gauge regularly. Avoid low fuel 1. Remove the fuel cap. Make sure the fuel tank is filled with
level and running out of fuel. Refuel in time. the correct fuel for the type of engine in the lift truck. See
Table 30.
WARNING
Stop the engine. Turn the key switch to OFF. The oper- 2. Install the fuel cap.
ator must be off of the lift truck while fuel is added.
Control Levers and Pedals
No smoking.
Check that the control levers for the transmission, mast,
All fuels for internal combustion engines are very flam- attachment, and the pedals operate as described in this
mable. manual.
Fill the fuel tank only in a designated area with good
ventilation. Have a fire extinguisher available.
193
Maintenance
Parking Brake Steering System

NOTE: The parking brake, when in good condition and cor-
WARNING
rectly adjusted, will hold a lift truck with a capacity load on a
The lift truck has hydraulic power steering. The steering
15% grade [a slope that increases 1.5m in 10 m (1.5 ft in
can be difficult when the engine is not running.
10 ft)].
Verify the steering system operates smoothly and gives good
NOTE: Always apply the parking brake when the truck is
steering control.
parked. A parking brake that is not applied will drain the bat-
teries. Boom, Rotator, and Spreader Operation
Check the operation of the parking brake. The parking brake
must apply when the knob for the parking brake is pulled. The WARNING
parking brake must release when the knob is pushed. Lower and retract the boom completely. Never allow
anyone under a raised carriage. Do not put any part of
Service Brakes your body in or through the lift mechanism unless all
parts of the mast are completely lowered and the engine
Check the operation of the service brakes. The service
is STOPPED.
brakes must apply when the service brake pedal or the
inching/brake pedal is depressed. Do not try to locate hydraulic leaks by putting hands on
pressurized hydraulic components. Hydraulic oil can be
NOTE: Slightly pushing the inching/brake pedal will apply the
injected into the body by pressure.
service brakes. Further pushing will fully disengage the
transmission. Do the following checks and inspections:
• Check for leaks in the hydraulic system. Check the con-
dition of the hydraulic hoses and tubes.
194
Maintenance
• Slowly raise and lower the boom several times without a angle of the boom. Fully derrick up the boom (use the over-
load. Extend and retract the boom at least once. The boom ride button to reach the maximum extension of the derrick
must raise and lower smoothly. cylinders), the display must show 59 d for the angle of the
boom.
• Check that the controls for the boom and spreader operate
the functions correctly. See the symbols by each of the Actual load indication: Pick up a container with a known
controls. weight of approximately 30 ton, verify that the actual load
indicated on the display is within ±750 kg of the actual weight
Signals From the Spreader Control System of the container.
Check that the control lights on the spreader and on the Load moment interrupt: Extend the container slowly, close to
TWIST module work correctly for the positions: seated, the ground, till the actual load is equal to the maximum load,
locked and unlocked. Verify that the increase of load moment is prohibited by the
extend- and derrick down interrupt.
Signals From the LLMS
Check LLMS indicator lights at startup and during operation.
Transmission
Have the LLMS repaired if it does not function as described Inspect for leaks. Make sure the transmission is shifting
in the operating manual. smoothly. If a problem is present, report this problem imme-
In order to check the correct functioning of the LLMS sensors, diately. DO NOT operate the lift truck until the problem is
check the boom angle/length sensor, actual load indication corrected.
and load moment interrupt. Operator Presence System
Boom angle/length sensor: Fully retract the boom, the dis-
NOTE: The Operator Presence System (OPS) is designed
play must show 0.0 m for the boom length. Fully extend the
to function after a slight delay (2.5 sec.) to allow the operator
boom, the display must show 6.6 m for the boom length. Fully
to reposition himself without disengaging the transmission.
derrick down the boom, the display must show 0 d for the
195
Maintenance
The OPS feature has an electrical switch in the seat, which How to Add Fuel to the ReachStacker
senses the presence of the operator. When the operator is
in the seat, the transmission can be engaged and hydraulic WARNING
functions can be operated. When the operator is absent, the Stop the engine. Turn the key switch to OFF. The oper-
transmission will disengage and hydraulic lift, lower, and tilt ator must be off of the ReachStacker while fuel is added.
functions cannot be operated.
No smoking.
In order to check operation of the OPS, you must raise your-
self from the seat for more than 2.5 sec. to make sure that All fuels for internal combustion engines are very flam-
the system will disengage the transmission and the hydraulic mable.
functions with the absence of the operator. Fill the fuel tank only in a designated area with good
• To reset the OPS for the hydraulic functions, the operator ventilation. Have a fire extinguisher available.
must be seated. Never fill the fuel tank near an open flame or near equip-
• To reset the OPS for the transmission, the operator must ment that can create sparks. Never check fuel level or
be seated and re-engage the transmission. check for leaks with an open flame.
To re-engage the transmission the operator must either: WARNING

• Depress the inching brake pedal more then 75%. Breathing fuel vapor may cause nausea, unconscious-
ness, or death. Long-term exposure to gasoline vapors
• Move the gear selector into the NEUTRAL position or and may cause liver or kidney damage and cancer. Avoid
then move the gear selector into travel mode. breathing vapor.
• Make a direction change using the MONOTROL® pedal. 1. Remove the fuel cap. Make sure to fill the tank with the
correct fuel. See Table 30. Clean the fuel cap.
2. Replace the fuel cap.
196
Maintenance
Completely remove the air pressure from the tire before
WARNING
it is removed from the ReachStacker. When dual wheels
When adding fuel, keep the funnel or fuel nozzle in con-
are installed, remove the air pressure from both tires. Air
tact with the metal of the fuel tank to reduce the possi-
pressure in the tires can cause the tire and wheel parts
bility of static electric sparks. Clean any spilled fuel.
to explode, causing serious injury or death.
Pneumatic Tires and Wheels ReachStacker wheels are very heavy, use caution when
removing wheels or personal injury may occur.
WARNING
The type of tire and tire pressure are shown on the 1. Raise the ReachStacker as described in How to Put a
nameplate. Make sure the nameplate is correct for the ReachStacker on Blocks in this manual.
type of tires on the ReachStacker. 2. Remove the air from the tire. Remove the valve core to
Remove Wheels From the ReachStacker make sure that all of the air is out of the inner tube. Push a
wire through the valve stem to make sure that the stem does
not have a restriction. If dual tires are installed, remove the
WARNING
air pressure from both tires. See Figure 37.
Wheels must be changed and tires repaired by trained
personnel only. 3. Remove the wheel nuts, then remove the wheel and tire
from the ReachStacker.
Always wear safety glasses.
197
Maintenance
A. STEER WHEEL B. DRIVE WHEELS

1. SIDE FLANGE 5. LOCK RING 9. WEDGE BAND
2. WHEEL RIM 6. O-RING 10. SPACER
3. FLANGE SEAT 7. RIM CLAMP 11. DRIVER
4. VALVE STEM 8. HUB
Figure 37. Wheel Arrangements
198
Maintenance
Remove Tire From the Wheel
WARNING
Keep tire tools in firm contact with wheels parts. If the
tool slips, it can move with enough force to cause seri-
ous injury. See Tire Removal From Five-Piece Wheel.
Tire Removal From Five-Piece Wheel
2. Push the flange seat downward and remove the seal ring.
1. Loosen the tire from the side flange. Remove the driver,
when installed. Remove the lock ring.
3. Remove the side flange and flange seat.
199
Maintenance
• DO NOT mix parts between different types or manu-
facturers of wheels.
• DO NOT mix types of tires, type of tire tread, or wheel
assemblies of different manufacturers on any one
ReachStacker.
Do not use a steel hammer on the wheel. Use a rubber,
lead, plastic, or brass hammer to put parts together.
Make sure that the lock ring is in the correct position.
4. Loosen the tire from the other side of the wheel rim. The ends of the lock ring must not touch. The clearance
Remove the side flange. Remove the rim from the tire. at the ends of the lock ring will be approximately 13 to
25 mm (0.5 to 1 in.) after it is installed. If the clearance is
Install Tire on the Wheel wrong, the wrong part has been used.
WARNING 1. Clean and inspect all parts of the wheel. Paint any parts
Wheels can explode and cause injury or death if the fol- that have rust or corrosion.
lowing procedures are not followed: 2. Install a new inner tube in the tire. Used tubes and flaps
• Clean and inspect all parts of the wheel before instal- can cause tire failure. Some inner tubes also require a
ling the tire. backup washer on the valve stem.
• DO NOT use any damaged or repaired wheel parts. 3. Apply a rubber lubricant or a soap solution to the tire bead
and tube.
• Make sure that all parts of the wheel are the correct
parts for that wheel assembly.
200
Maintenance
1. Put the rim on blocks. Install the side flange. Make sure
WARNING
the side flange is engaged with the rim.
Do not lubricate the tire bead with antifreeze or petro-
leum-based liquid. Vapors from these liquids can cause
an explosion during inflation or use.
4. Install a new tire flap. Used tubes and flaps can cause tire
failure.
5. Make sure the rim is the correct size for the tire. Lubricate
the part of the wheel that contacts the bead and flap.
6. Install the tire in the wheel as shown in Tire Installation
on Five-Piece Wheel.
Tire Installation on Five-Piece Wheel
2. Install the valve stem in the rim. Install the tire on the rim.
3. Install the flange seat and side flange.
201
Maintenance
Add Air Pressure to the Tires
WARNING
Add air pressure to the tires only in a safety cage.
Inspect the safety cage for damage before use. When air
pressure is added to the tire, use an air chuck that fas-
tens onto the valve stem of the inner tube. Make sure
4. Push the flange seat down for access to the groove for the there is enough air hose to permit the operator to stand
seal ring. Install the seal ring. away from the safety cage when air pressure is added to
the tire.
Do not sit or stand by the safety cage. Do not use a ham-
mer to try and correct the position of the side flange or
lock ring when the tire has air pressure greater than
20 kPa (3 psi).
1. Put the tire in a safety cage. See Figure 38.
2. Add 20 kPa (3 psi) of air pressure to the tire.
5. Install the lock ring. Make sure all parts are correctly 3. Check that all wheel parts are correctly installed. See Fig-
aligned. When correctly installed, there will be a 13 to 25 mm ure 38. Hit the lock ring lightly to make sure that it is in the
(0.5 to 1.00 in.) clearance between the ends of the side ring seat.
and/or the lock ring. If removed, install the driver in the lug. 4. If installation is correct, add air to the tire to the specified
Add air pressure to the tire as described in Add Air Pressure pressure.
to the Tires.
202
Maintenance
5. Check that all wheel parts are correctly installed. If instal- Install Wheels on the ReachStacker
lation is not correct, remove all of the air pressure from the
tire. Remove the valve core to make sure all of the air pres- Align and install the wheel(s) and tire(s) on the hub.
sure has been removed and make adjustments. The clear- Use the sequence shown in Figure 39. First, tighten the nuts
ance at the ends of the lock ring will be 13 to 25 mm (0.5 to to 35 N•m (26 lbf ft), then tighten to 100 N•m (74 lbf ft). Check
1.0 in.) when the tire has the correct air pressure. for correct alignment of wheel parts and inside wheel-to-hub
alignment after tightening nuts 1 through 4. Finally, tighten
the nuts to the torque value shown in the Maintenance
Schedule and Figure 39.
CAUTION
Check all wheel nuts after 2 to 5 hours of operation:
when new ReachStacker begin operation and on all
ReachStacker when the drive wheels have been
removed and installed. Tighten the nuts as shown in
Figure 39. When the nuts stay tight for eight hours, the
interval for checking the torque can be extended to 500
hours.
Figure 38. Add Air to the Tires
203
Maintenance
A. STEER WHEEL C. DRIVE WHEEL KESSLER

B. DRIVE WHEEL AXLE TECH
Figure 39. Wheel Nut Tightening Sequence

How to Put Internal Combustion Engine (ICE) Before placing any ReachStacker in storage, you must
ReachStacker in Storage choose an area that is clean, dry, and free from airborne
contaminates. For safety and increased usable floor area,
It is important to store your ReachStacker properly to protect remove the forks and tag them with the ReachStacker serial
it. The main areas of concern are engines, hydraulic com- number. For best protection, operate your internal combus-
ponents, and truck batteries. The length of storage time and tion engine ReachStacker for a short period each month.
the storage location determines what procedures you should
The following storage procedures are for conditions and tem-
follow.
peratures above 0 °C (32 °F). Adjust these procedures for
local conditions and any changes in conditions during
204
Maintenance
storage. The preparations necessary for storage are also 5. Install blocks, front and rear, at the drive wheels. If the
determined from the following conditions: ReachStacker must be left on an incline, put blocks on the
downhill side of all wheels so that the ReachStacker cannot
• Short-term storage is from one to six months. Long-term
move. DO NOT USE THE PARKING BRAKE.
storage is over six months.
6. Disconnect the battery cables from the battery Apply a
• Storage Location. A ReachStacker stored indoors will not
protective coating to the cable connectors and battery termi-
require as much external protection as a ReachStacker
nals to prevent corrosion.
stored outdoors.
7. Check the tire pressure, if applicable. Make sure the tires
Short-Term Storage have the correct pressure (see the Nameplate).
Perform the following steps to prepare your ReachStacker 8. Clean the ReachStacker and engine compartment to pre-
for storage from one to six months: vent corrosion.
1. Change engine oil. Check lubricant and fluid levels. Com- 9. If the ReachStacker is not stored indoors, put a cover over
pletely fill the fuel tank. Make sure the coolant mixture will the ReachStacker to prevent damage from the weather. In
protect cooling system and engine to lowest temperature wet conditions, a cover will not prevent corrosion to the
expected during storage. Make sure all caps and dipsticks ReachStacker.
are installed correctly.
Long-Term Storage
2. Fully lower and retract the boom. Apply a thin coat of fresh,
high grade SAE 30 or 40 weight engine oil to the exposed Do the following steps to prepare the ReachStacker for stor-
cylinder rods. age for 6 months or longer:
3. Check that all switches and accessories are in the OFF 1. Complete all short-term storage procedures.
position.
4. Activate each control lever to relieve hydraulic pressure.
205
Maintenance
2. Wrap or cover all exterior lights, radiator grill, and air vents Each month all hydraulic cylinders must be cycled several
with a moisture barrier cover. Use tape to hold the covers in times to keep the seals active and to coat the interior walls
place. with oil. Actuate each cylinder, in both directions, until it rea-
ches the stops.
3. Remove the battery or batteries from the ReachStacker.
Store the battery or batteries in an approved space. Be sure Return ReachStacker to its storage state for another month.
to follow local regulations. Batteries that are stored for long
periods can become damaged. Either keep batteries in serv- How to Put Batteries in Storage
ice or follow the battery storage procedures below. Batteries are to be placed on a wooden pallet and stored in
4. Spray exterior surfaces and frame with preservative coat- a dry, moderately cool area.
ing. Lead acid batteries will slowly "self-discharge" over a period
While the ReachStacker is in Storage of time due to their chemical makeup. If the self-discharge is
left uncontrolled, excessive sulphation can occur which is
Each month make a visual inspection for leaks or signs of difficult to reduce and can damage the anodes. A discharged
deterioration. Take corrective action immediately. Check the battery with a specific gravity of 1.000 will freeze at −7.8 °C
fluid level in engine, radiator, hydraulic tank, and brake mas- (18 °F). A fully-charged battery with a specific gravity of 1.280
ter cylinder. will freeze at −66 °C (87 °F).
NOTE: DO NOT shut down an engine before it reaches This "self-discharge" discharge is due to a chemical reaction;
operating temperature. therefore, that chemical reaction can be accelerated by heat
resulting in more rapid "self-discharge". The rate of dis-
Each month set the park brake, start engine, and run until
charge can amount to an average of about 0.001 point drop
normal operating temperature is reached. This will coat the
in specific gravity per day.
internal engine components with a film of oil and rid the
engine of built-up condensation.
206
Maintenance
The following procedure can be followed when placing a bat- 2. Check the ReachStacker for damage and missing com-
tery in storage or when not in operation for more than 30 ponents. Repair damage and/or replace missing compo-
days. nents.
1. Give an equalizing charge prior to placing new batteries in NOTE: If the ReachStacker has been stored longer than one
storage. Used batteries are to be fully charged, then allowed year, all lubricants and fluids must be drained and replaced,
to balance for approximately three more hours. or perform oil analysis to determine condition of lubricant and
replace, if necessary. See the Periodic Maintenance sec-
2. Neutralize and clean the battery. Clean with a solution of
tion of your Service Manual for the procedures.
100 grams (3.5 oz) of sodium bicarbonate (baking soda) per
1 liter (0.25 gal) of water. 3. Clean the battery cables and terminals. Check the battery
voltage. If the voltage is not correct, charge battery. Connect
3. Store in a cool, dry location.
battery cables to battery.
4. Check each cell in the battery at least once every 30 days
4. When a ReachStacker is to be put into service after stor-
and boost charge when specific gravity falls below 1.240 Hg.
age, it must be given the 500-hour inspection shown in the
5. Protect batteries from ambient contamination. Recommended Schedule of Maintenance.
If a greasy film forms on the top of a battery, this is acid and How to Move a ReachStacker on a Transport
must be neutralized with the solution described above.
Putting a Stored ReachStacker Back Into WARNING
Stay a safe distance from the edge of docks, ramps,
Service platforms, and other similar working surfaces. Watch
1. Remove all tape, covers, and preservation materials. the "tail swing". Remember when traveling in the for-
ward direction and the steering wheel is turned to move
the ReachStacker away from the edge of the dock, the
207
Maintenance
rear will swing toward the edge. This can cause the Loading
ReachStacker to fall off the dock.
WARNING
WARNING The straps or chains used to fasten the ReachStacker to
IF THE ReachStacker FALLS OFF THE DOCK, DO NOT the transport must be directly connected to the Reach-
JUMP OFF! HOLD FIRMLY TO STEERING WHEEL, Stacker frame or to a component (drive axle, tow pin)
BRACE YOUR FEET, AND LEAN FORWARD AND AWAY that is solidly attached to the frame. DO NOT fasten a
FROM THE POINT OF IMPACT. strap or chain to the mast or any attachment to hold the
Before the ReachStacker is moved on transport, check the ReachStacker on the transport.
selected route to make sure there is enough clearance for
the ReachStacker as loaded on the transport vehicle. CAUTION
Bridges, overpasses, power lines, and natural barriers can Make sure that any straps or chains used to fasten the
prevent clearance. Removal of the mast can be necessary. ReachStacker to the transport DO NOT contact any
tubes, hoses, hydraulic cylinders, or other parts of the
If a trailer is the method of transportation, use blocks in front ReachStacker that are easily damaged.
and back of the trailer tires to prevent movement of the trailer
when the ReachStacker is loaded and unloaded. If a loading If components and attachments must be removed for trans-
ramp is used, make sure that the ramp is the correct design port of the ReachStacker, see the Service Manual for
and capacity. removal procedures.
A crane can only be used to load or unload the ReachStacker The operator must never leave a ReachStacker in a condition
if the ReachStacker is equipped with lifting eyes. Otherwise, so that it can cause damage or injury. When the Reach-
the ReachStacker must be driven on or off the transport. Stacker is loaded on the transport, do the following opera-
tions:
1. Apply the parking brake.
208
Maintenance
2. If the boom is mounted on the ReachStacker, fully lower 3. Disconnect the straps or chains.
the boom.
4. Remove the wheel blocks.
3. Put the direction control lever for the powershift transmis-
5. If the ReachStacker is equipped with lifting eyes and a
sion in NEUTRAL (N). If the ReachStacker has a manual
crane is to be used to unload, check that all switches and
transmission, leave the gears of the transmission engaged.
accessories are turned OFF.
DO NOT leave a manual transmission in NEUTRAL (N).
6. If ReachStacker is to be driven off transport, follow starting
4. Turn the key switch to OFF to stop the engine. Check that
procedures.
all switches and accessories are turned OFF.
7. Unload the ReachStacker.
5. Put blocks in front and back of the ReachStacker tires to
prevent any movement of the ReachStacker. Make sure the Preparation After Transport
blocks are attached to the load surface.
After being transported, the ReachStacker must be prepared
6. If the ReachStacker is transported in severe weather or for proper operation. All problems must be corrected before
any other condition that can damage the ReachStacker, use of the ReachStacker, see the Service Manual for pro-
cover the ReachStacker. Make sure the protective cover is cedures. Perform the following operations:
designed for the application and is securely fastened.
1. Complete the unloading procedures.
Unloading
2. If components normally attached to the ReachStacker
When the ReachStacker is to be unloaded from the transport, were removed for transport, see the Service Manual for
perform the following operations: assembly instructions.
1. If used, remove any protective cover. 3. Inspect the ReachStacker for damage and missing com-
ponents. Repair or replace as necessary.
2. Make sure the parking brake is applied.
209
Maintenance
4. Follow the steps in the section How to Make Checks With 3. If the work conditions are slow and the loads are less than
the Engine Stopped. 50 percent of the ReachStacker capacity, a simulated work
condition must be used during the first 4 hours of operation.
Operating Procedures for a New or Rebuilt Operate the ReachStacker with a minimum load of 75 per-
Engine cent capacity. Operate the engine through cycles from idle
to full throttle and back to idle. Avoid long periods of high
A new or rebuilt engine must be operated under special con-
engine speeds with a light load during the first 50 hours of
ditions during the first 50 hours. These special conditions
operation. High engine speeds with a light load can cause
prevent damage to the engine until the new parts can wear
damage to the cylinders in the engine.
some for normal clearances.
4. Have your dealer perform the necessary checks and
1. Make sure the fluid levels of oil and coolant are correct.
adjustments on the engine.
2. Start and run the engine at approximately one-half throttle
for 30 minutes for the first operation. Check the gauges and
indicators for the correct operation during this first operating
period. Check for leaks.
210
Maintenance
Maintenance Register
Protect your investment in materials handling equipment! This Maintenance Register is used to record the time of
Keep a high-residual value in your Hyster ! Do the mainte- each periodic inspection and maintenance. The dealer's
nance according to the Maintenance Schedule in this Oper- stamp or authorized signature confirms that maintenance
ating Manual. and inspection was done at regular intervals by authorized
personnel.
Your dealer for Hyster has the equipment and trained serv-
ice personnel to do a complete program of inspection, lubri-
cation, and maintenance.
1. 2. 3. 4.
Operating Hours ________ Operating Hours ________ Operating Hours ________ Operating Hours ________
Date _________________ Date _________________ Date _________________ Date _________________
5. 6. 7. 8.
9. 10. 11. 12.
13. 14. 15. 16.
211
Maintenance
17. 18. 19. 20.

21. 22. 23. 24.
25. 26. 27. 28.
29. 30. 31. 32.
33. 34. 35. 36.
37. 38. 39. 40.
41. 42. 43. 44.
212
Spacer
2/14 (4/13)(1/13)
OPERATING MANUAL
ReachStacker
RS45-27, 31 CH; RS46-36, 41L, 41S, 41LS CH;

RS45-24, 28 IH;RS46-33, 38L, 38S, 38LS IH;
(C222) SN E1609 => and also (C222) SN E1601
DO NOT REMOVE THIS MANUAL FROM THIS UNIT
PART NO. 4073819 2/14

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OPERATING MANUAL

RS45-27, 31 CH; RS46-36, 41L, 41S, 41LS CH;

DO NOT REMOVE THIS MANUAL FROM THIS UNIT

PART NO. 4073819 2/14

LIFT TRUCK MODEL SERIAL NUMBER

ENGINE MODEL SERIAL NUMBER

TRANSMISSION TYPE SERIAL NUMBER

MAST LIFT HEIGHT GROUP NUMBER

CARRIAGE TYPE GROUP NUMBER

DRIVE TIRE SIZE STEERING TIRE SIZE

SPECIAL EQUIPMENT OR ATTACHMENTS

© Hyster Company 2014. All rights reserved.

©HYSTER COMPANY 2014 4073819 - ENGLISH-UK 1

Average ambient temperature for continuous duty: +45°C

Lifting 1. Arrange for the modification or alteration to be designed,

Truck Length Engine Travel Speed Gradeability

Truck Length Engine Travel Speed Gradeability

Truck Length Engine Travel Speed Gradeability

Truck Length Engine Travel Speed Gradeability

DECLARE UNDER OUR SOLE RESPONSIBILITY THAT THE MACHINE

CATEGORY: FORKLIFT IC ENGINE POWERED

IS IN CONFORMITY WITH THE MACHINERY DIRECTIVE 2006/42/EC. COMPLIANCE WITH

OTHER APPLICABLE DIRECTIVES:

KNOW THE EQUIPMENT: LOOK WHERE YOU ARE GOING:

• BE in complete control at all times. • DO NOT start if fuel is leaking.

FAILURE TO FOLLOW THESE INSTRUCTIONS CAN

Figure 1. Model View Showing Major Components

A. NAMEPLATE B. NOTICE LABEL C. INCOMPLETE LABEL D. SAMPLE CAPACITY CHART

Figure 2. Nameplate and Label

Figure 3. Warning and Safety Labels

Controls, Instruments, Indicators, and

A. AIR SEAT B. MECHANICAL SEAT

Figure 4. Seat Controls

Item Item Function

Item Item Function

Figure 5. Sears Deluxe Seat

Item Item Function

Item Item Function

Item Item Function

Figure 6. Spring-Assisted Armrest

Item No. Item Function

Figure 7. Instrument and Indicators (Sheet 1 of 2)

Figure 7. Instrument and Indicators (Sheet 2 of 2)

Code Starts With System Reference or Explanation

Code Explanation Operator Action

Code Explanation Operator Action

Controls 1. LCD Display

speed are displayed. A symbol will be displayed when there is any

Blower Speed Settings:

Climate Control Mode Settings:

Turning HVAC System OFF:

Figure 8. Switches on Side Console

Item Item Function

Item Item Function

4 Heat Control Knob Knob controls the heater valve.

Item Item Function

Item Item Function

Item Item Function

Item Item Function