FRAME

RS45-30CH, RS45-27IH, RS46-33CH, RS46-30IH,

RS46-36CH, RS46-33IH Up to 1562, 1564,
1565, and 1569 [A222]

PART NO. 897945 100 SRM 631

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair

on electric lift trucks. Disconnect the battery ground cable on internal combustion lift
trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Mainte-
nance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs,
or if the unit needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this
manual:

WARNING
Indicates a condition that can cause immediate death or injury!

CAUTION
Indicates a condition that can cause property damage!
Frame Table of Contents

TABLE OF CONTENTS

General ............................................................................................................................................................... 1
Description ......................................................................................................................................................... 1
Counterweight.................................................................................................................................................... 2
Remove ........................................................................................................................................................... 2
Install ............................................................................................................................................................. 3
Fenders ............................................................................................................................................................... 3
Front Fender .................................................................................................................................................. 3
Remove....................................................................................................................................................... 3
Install ......................................................................................................................................................... 4
Rear Fender ................................................................................................................................................... 4
Remove....................................................................................................................................................... 4
Install ......................................................................................................................................................... 5
Hydraulic Tank Platform................................................................................................................................... 5
Remove ........................................................................................................................................................... 5
Repair ............................................................................................................................................................. 7
Small Leaks ............................................................................................................................................... 7
Large Leaks ............................................................................................................................................... 7
Clean .............................................................................................................................................................. 7
Steam Method............................................................................................................................................ 7
Chemical Solution Method........................................................................................................................ 8
Other Methods of Preparation for Repair .................................................................................................... 8
Install ............................................................................................................................................................. 8
Fuel Tank Platform............................................................................................................................................ 8
Remove ........................................................................................................................................................... 8
Repair ............................................................................................................................................................. 10
Install ............................................................................................................................................................. 10
Transmission Oil Cooler .................................................................................................................................... 11
Remove ........................................................................................................................................................... 11
Install ............................................................................................................................................................. 12
Radiator Repair.................................................................................................................................................. 12
Remove ........................................................................................................................................................... 12
Install ............................................................................................................................................................. 12
Exhaust System ................................................................................................................................................. 13
Remove ........................................................................................................................................................... 13
Install ............................................................................................................................................................. 13
Engine Removal and Installation ..................................................................................................................... 14
Remove ........................................................................................................................................................... 14
Install ............................................................................................................................................................. 14
Operator Compartment ..................................................................................................................................... 15
General ........................................................................................................................................................... 15
Tilting ............................................................................................................................................................. 15
Lowering......................................................................................................................................................... 15
Remove ........................................................................................................................................................... 16
Install ............................................................................................................................................................. 18
Gauges and Switches..................................................................................................................................... 18
Window Wipers .................................................................................................................................................. 22
Single Arm Unit (Rear Window) ................................................................................................................... 23
Remove....................................................................................................................................................... 23
Install ......................................................................................................................................................... 23
Single Arm Unit (Top Window) ..................................................................................................................... 23
Remove....................................................................................................................................................... 23

©2005 HYSTER COMPANY i

Table of Contents Frame

TABLE OF CONTENTS (Continued)

Install ......................................................................................................................................................... 23
Double Arm Unit ........................................................................................................................................... 23
Remove....................................................................................................................................................... 23
Install ......................................................................................................................................................... 23
Window Washer Motor/Pumps .......................................................................................................................... 24
Remove ........................................................................................................................................................... 24
Install ............................................................................................................................................................. 24
Heater Assembly ................................................................................................................................................ 24
Remove ........................................................................................................................................................... 24
Install ............................................................................................................................................................. 24
Door Handle Assembly ...................................................................................................................................... 26
Remove ........................................................................................................................................................... 26
Install ............................................................................................................................................................. 26
Window Replacement......................................................................................................................................... 27
Windshield ..................................................................................................................................................... 27
Remove....................................................................................................................................................... 27
Install ......................................................................................................................................................... 27
Rear Window.................................................................................................................................................. 27
Remove....................................................................................................................................................... 27
Install ......................................................................................................................................................... 27
Top Window .................................................................................................................................................... 27
Remove....................................................................................................................................................... 27
Install ......................................................................................................................................................... 27
Operator Restraint System ............................................................................................................................... 28
Label Replacement............................................................................................................................................. 28

This section is for the following models:

RS45-30CH, RS45-27IH, RS46-33CH, RS46-30IH, RS46-36CH, RS46-33IH

Up to 1562, 1564, 1565, and 1569 [A222]

ii
100 SRM 631 Description

General
This section has the description and repair proce-
WARNING dures for the ReachStacker frame and connected
When using an arc welder, always disconnect parts. Included in this section are the frame, coun-
the ground lead from the lift truck batteries terweight, fenders, hood, hydraulic and fuel tank
to prevent alternator or battery damage. At- platforms, radiator, and operator compartment.
tach the welding ground clamp as close to the The instructions for removal and installation of the
weld area as possible to prevent welding cur- engine are included in this section.
rent from damaging bearings.

Description
The frame is a one-piece weldment and has mounts axles, hydraulic tank platform and fuel tank plat-
for the counterweight, fenders, engine, transmission, form, operator’s compartment, and other parts. See
Figure 1.

1. SPREADER 6. CAB/OPERATOR’S COMPARTMENT

2. BOOM 7. HOIST CYLINDERS
3. COUNTERWEIGHT 8. HYDRAULIC TANK PLATFORM
4. STEERING AXLE 9. MAIN FRAME
5. DRIVE AXLE

Figure 1. Model View Showing Major Frame Components

1
Counterweight 100 SRM 631

Counterweight
REMOVE
WARNING
The rear counterweight weighs 3350 kg
(7387 lb), and the main counterweight weighs
12,500 kg (27,563 lb). Make sure that a lifting
device capable of lifting these weights is avail-
able before starting the removal or installation
procedures.
1. Attach a lifting device to the two lift points of the
rear counterweight. See Figure 2. Remove the
four attaching nuts, four washers, four bolts, and
counterweight from the main counterweight.
2. Attach a lifting device to the four lift points of
the main counterweight. Remove four nuts, four
washers, four bolts, and main counterweight
from the ReachStacker®.

1. REAR COUNTERWEIGHT 3. COUNTERWEIGHT LIFT POINTS

2. COUNTERWEIGHT MOUNTING BOLTS 4. MAIN COUNTERWEIGHT

Figure 2. Counterweights

2
100 SRM 631
INSTALL
WARNING
The rear counterweight weighs 3350 kg
(7387 lb), and the main counterweight weighs
12,500 kg (27,563 lb). Make sure that a lifting
device capable of lifting these weights is avail-
able before starting the removal or installation
procedures.
Fenders
FRONT FENDER
Remove
WARNING
The front fenders are heavy. Make sure any lift-
ing devices used to remove or install the front
fenders have the capacity to lift 140 kg (309 lb).
Figure 3. Front Fender Assembly
Fenders
1. Attach a lifting device to the four lift points of the
main counterweight. Install the main counter-
weight onto the ReachStacker. Install four bolts,
four washers, and four nuts. Tighten the four
bolts to 1220 N•m (900 lbf ft).
2. Install the rear counterweight onto the main
counterweight. Install the four bolts, four wash-
ers and four nuts. Tighten the bolts to 1500 N•m
(1100 lbf ft).
1. Remove the headlight assembly from the fender.
See Figure 3.
2. Remove the nuts, washers, and bolts from the
inside front of the fuel tank compartment or the
hydraulic oil compartment.
3. Attach the lifting device and remove the nuts,
washers, and bolts from the top of the fender.
3
Fenders 100 SRM 631

4. Lift the fender clear of the frame. REAR FENDER

Install
1. Lift the fender onto the frame.
2. Install the bolts, washers, and nuts into the top
of the fender to be installed.
3. Install the bolts, washers, and nuts into the in-
side front of the fuel tank compartment or the
hydraulic oil compartment.
Remove
WARNING
The rear fenders are heavy. Make sure any lift-
ing devices used to remove or install the rear
fenders have the capacity to lift 100 kg (221 lb).
1. Remove the backup light and the combination
light assembly from the fender. See Figure 4.

4. Install the headlight assembly onto the fender. 2. Remove the lower step from the rear fender and
platform assembly.

1. BACKUP LIGHT 3. LOWER STEP

2. COMBINATION LIGHT 4. REAR FENDER

Figure 4. Rear Fender Assembly

4
100 SRM 631
3. Support the fender and remove the nuts, wash-
ers, bolts, and fender from the frame.
Install
WARNING
The rear fenders are heavy. Make sure any lift-
ing devices used to remove or install the rear
fenders have the capacity to lift 100 kg (221 lb).
Hydraulic Tank Platform
The hydraulic tank platform is located on the left side
of the ReachStacker®. See Figure 5. Located within
the hydraulic tank platform are the boom main con-
trol valves, pilot-assisted over-center valve, pilot-as-
sisted relief valve, hydraulic system pressure test
block, and the hydraulic system oil cooler.
REMOVE
WARNING
The hydraulic oil tank contains 900 liter
(238 gal) of hydraulic oil. Drain the oil from
the tank before removing the hydraulic plat-
form assembly. Failure to drain the tank could
result in an oil spill.
After use of the hydraulic system, the hy-
draulic oil is very hot. Do not begin any
maintenance procedures until the hydraulic
oil has cooled. Monitor the temperature of the
hydraulic oil observing the temperature gauge
on the outside of the hydraulic tank.
1. Drain the hydraulic oil into clean barrels.
2. Remove the handrail, walkway covers, and lower
step from the hydraulic tank platform.
3. Remove the front and rear fenders. See Front
Fender, Remove and Rear Fender, Remove.
Hydraulic Tank Platform
1. Install the fender onto the frame.
2. Install the bolts, washers, and nuts.
3. Install the lower step onto the rear fender and
platform assembly.
4. Install the combination light assembly and the
backup light onto the fender to be installed.
WARNING
Rotate the battery disconnect switch to the off
position before disconnecting any electrical
connectors.
4. Disconnect all electrical connectors and tag con-
nectors to aid in the installation.
5. Disconnect the hydraulic hoses and tubes from
the hydraulic tank, boom control valves, pilot
assisted over-center valve, pilot pressure relief
valve, and hydraulic system pressure test block.
Use a pan to catch the oil that is in the hydraulic
lines. Put tags on the lines and tubes for identi-
fication. Put caps on the open lines and the fit-
tings.
WARNING
The hydraulic tank platform weighs 2350 kg
(5182 lb). Make sure the lifting device used to
remove the hydraulic tank platform is rated for
at least the weight of the platform.
CAUTION
Make sure the hydraulic hose and the electrical
cables are not damaged during the removal of
the hydraulic platform.
6. Attach a lifting device to the hydraulic tank plat-
form, and remove the hydraulic tank platform
from the frame weldment.
5
Hydraulic Tank Platform 100 SRM 631

Figure 5. Hydraulic Tank Platform

6
100 SRM 631
Legend for Figure 5
A. HYDRAULIC VALVE CONNECTIONS AT THE
INSIDE FRONT OF THE HYDRAULIC TANK
PLATFORM
1. HYDRAULIC TANK PLATFORM
2. HANDRAIL
REPAIR
Small Leaks
Use the following procedures to repair small leaks:
1. Use steam to clean the area around the leak. Re-
move all paint and dirt around the leak.
WARNING
Do not use tools that can make sparks, heat, or
static electricity. The vapors in the tank can
cause an explosion.
2. Apply Loctite 290 to the leak. Follow the instruc-
tions of the manufacturer.
Large Leaks
1. Use one of the procedures described under Clean
to clean and prepare the tank for repairs.
2. Use acceptable welding practices to repair the
tank. See the American National Standard
Safety in Welding and Cutting AWS Z 49.1 -
1999.
CLEAN
WARNING
Special procedures must be followed when
large leaks or other repairs need welding or
cutting. All work must be done by authorized
personnel. If the tank is cleaned inside of a
building, make sure there is enough ventila-
tion. See the following manuals for additional
information:
• "Safe Practices For Welding And Cutting Con-
tainers That Have Held Combustibles" by the
American Welding Society, F4.1 - 1999.
• "Safety In Welding and Cutting", American
National Standard, AWS Z 49.1 - 1999.
When cleaning the tank, do not use solutions that
make dangerous gases at normal temperatures or
when heated. Wear device for the protection of the
eyes. Protect the body from burns.
Hydraulic Tank Platform
B. HYDRAULIC TANK CONNECTIONS AT THE
INSIDE REAR OF THE HYDRAULIC TANK
PLATFORM
3. LOWER STEP
When cleaning with steam, use a hose with a mini-
mum diameter of 19 mm (0.75 in.). Control the pres-
sure of the steam by a valve installed at the nozzle of
the hose. If a metal nozzle is used, it must be made of
a material that does not make sparks. Make an elec-
trical connection between the nozzle and the tank.
Connect a ground wire to the tank to prevent static
electricity.
Steam Method
Use the following procedure to clean the tank with
steam:
1. Remove all the parts from the tank. Install the
drain plug.
2. Fill the tank 1/4 full with a solution of water and
sodium bicarbonate or sodium carbonate. Mix
0.5 kg (1 lb) per 4 liter (1 gal) of water.
3. Mix the solution in the tank using air pressure.
Make sure all the surfaces on the inside of the
tank are flushed with the solution. Drain the
tank.
4. Put steam into the tank until the tank does not
have odors and the metal is hot. Steam vapors
must come from all the openings.
5. Flush the inside of the tank with boiling water.
Make sure all the loose material is removed from
the inside of the tank.
6. Make an inspection of the inside of the tank. If
it is not clean, repeat Step 4 and Step 5 and
make another inspection. When making inspec-
tions, use light that is approved for locations with
flammable vapors.
7. Put plugs in all the openings in the tank. Wait 15
minutes, then remove the inlet and outlet plugs.
Test a sample of the vapor with a special indi-
cator for gas vapors. If the amount of flammable
vapors is above the lower flammable limit, repeat
the cleaning procedures.
7
Fuel Tank Platform
Chemical Solution Method
If the tank cannot be cleaned with steam, use the
following procedure:
1. Mix a solution of water and trisodium phosphate
or a cleaning compound with an alkali base. Fol-
low the instructions given by the manufacturer.
2. Fill the tank with the cleaning solution. Use com-
pressed air to mix the solution in the tank.
3. Drain the tank. Flush the inside of the tank with
hot (boiling) water. Make sure all the cleaning
compound is removed.
4. Make an inspection of the inside of the tank. If
the tank is not clean, repeat Step 1 to Step 3.
Make another inspection of the tank. When mak-
ing inspections, use a light that is approved for
locations with flammable vapors.
5. Check the tank for flammable vapors using
special indicator for gas vapors. If the amount
of flammable vapors is not below the lower
flammable limit, repeat the cleaning procedures.
OTHER METHODS OF PREPARATION FOR
REPAIR
If nitrogen gas or carbon dioxide gas is available, pre-
pare the tank for welding using these gases. See the
manual Safe Practices For Welding and Cutting Con-
tainers That Have Held Combustibles by the Ameri-
can Welding Society, F4.1 - 1999. If these gases are
not available, another method using water can be
used as follows:
1. Fill the tank with water to just below the point
where the work will be done. Make sure the
space above the level of the water has a vent.
Fuel Tank Platform
The fuel tank platform is installed on the right-hand
side of the ReachStacker frame weldment. See Fig-
ure 6.
REMOVE
WARNING
If the fuel is drained from the fuel tank, put the
fuel in a barrel that has a sealed cap to prevent
contamination of the fuel.
8
100 SRM 631
2. Use acceptable welding practices to repair the
tank. See the American National Standard
Safety In Welding and Cutting AWS Z 49.1 -
1999.
INSTALL
WARNING
The hydraulic tank platform weighs 2350 kg
(5182 lb). Make sure the lifting device used to
install the hydraulic tank platform is rated for
at least the weight of the platform.
1. Attach a hoist to the hydraulic tank platform,
and install the hydraulic tank platform onto the
frame weldment.
2. Connect the hydraulic hoses and tubes to the hy-
draulic tank, boom control valves, pilot-assisted
over-center valve, pilot pressure relief valve, and
hydraulic system pressure test block as tagged
during removal.
3. Connect all electrical connectors as tagged dur-
ing removal.
4. Install the lower step, walkway covers, and
handrail onto the hydraulic tank platform.
5. Install the front and rear outer fenders. See
Front Fender, Install and Rear Fender, Install.
6. Fill the hydraulic tank to the correct level with
the oil specified in the maintenance table. See
the section Periodic Maintenance, Reach-
Stacker 8000 SRM 592.
1. If necessary, remove the drain plug to drain the
fuel from the tank.
2. Remove the handrail, walkway covers, and lower
step from the fuel tank platform.
3. Remove the front and rear fenders. See Front
Fender, Remove and Rear Fender, Remove.
100 SRM 631 Fuel Tank Platform

A. POWER DISTRIBUTION PANEL AT THE INSIDE
OF THE REAR TANK PLATFORM DOOR
1. FUEL TANK PLATFORM
2. HANDRAIL
B. HYDRAULIC BRAKE CONNECTIONS AND CAB
TILT PUMP AT THE INSIDE OF THE FRONT
FUEL TANK PLATFORM DOOR
3. LOWER STEP

Figure 6. Fuel Tank Platform

9
Fuel Tank Platform
4. Disconnect the fuel lines at the fuel tank. Use a
pan to catch the fuel that is in the lines. Put tags
on the lines and tubes for identification.
5. Disconnect the brake system hydraulic hoses and
tubes from the accumulator, thermostatic bypass
valve, accumulator charge valve, pressure check
port, pressure solenoid valves, return manifold,
flow divider, and check valve. Use a pan to catch
the oil that is in the lines. Put tags on the lines
and tubes for identification. Put caps on the open
lines and the fittings.
6. Disconnect the hydraulic lines from the cab tilt
hand pump. Use a pan to catch the oil that is
in the lines. Put tags on the lines and tubes for
identification. Put caps on the open lines and the
fittings.
WARNING
Make sure the battery disconnect switch is in
the off position before disconnecting or con-
necting cables.
7. Disconnect all cables from the main power distri-
bution box. Put tags on the cables for identifica-
tion.
8. Remove the main power distribution box from
the fuel tank platform.
WARNING
The batteries are very heavy and should not be
lifted without the assistance of another person.
9. Disconnect the cables from the batteries, and re-
move the batteries from the access door.
WARNING
The fuel tank platform weighs 2350 kg (5182 lb).
Make sure the lifting device used to remove
the fuel tank platform is rated for at least the
weight of the platform.
CAUTION
Do not damage the hydraulic hose and the
electrical cables during the removal of the
hydraulic platform.
10
100 SRM 631
10. Attach a lifting device to the fuel tank platform,
and remove the fuel tank platform from the
frame weldment.
REPAIR
WARNING
Do not use tools that can make sparks, heat, or
static electricity. The vapors in the tank can
cause an explosion.
Repair the fuel tank as described in the repair proce-
dures for the hydraulic tank.
INSTALL
WARNING
The fuel tank platform weighs 2350 kg (5182 lb).
Make sure the lifting device used to remove the
hydraulic tank platform is rated for at least the
weight of the platform.
1. Attach a hoist to the fuel tank platform, and in-
stall the fuel tank platform onto the frame weld-
ment. See Figure 6.
2. Install the main power distribution box into the
fuel tank platform. Connect all cables to the
main power distribution box as tagged during re-
moval.
3. Install the batteries onto the access door, and
connect the cables to the batteries.
4. Connect the hydraulic lines to the cab tilt hand
pump as tagged during removal.
5. Connect the brake system hydraulic hoses and
tubes to the accumulator, thermostatic bypass
valve, accumulator charge valve, pressure check
port, pressure solenoid valves, return manifold,
flow divider, and check valve.
6. Connect the fuel lines to the tank.
7. Install the lower step, walkway covers, and the
handrail onto the fuel tank platform.
8. Fill the fuel tank to the proper level.
100 SRM 631 Transmission Oil Cooler

Transmission Oil Cooler

REMOVE 2. Disconnect the transmission oil hoses from the
top of the transmission oil cooler. Use a pan to
1. Remove the air intake tube from the tur- catch the transmission oil that is in the lines.
bocharger and the air cleaner. See Figure 7.

1. RESERVOIR 14. WASHER 26. WASHER

2. CAP 15. TRANSMISSION OIL 27. NUT
3. CLAMP COOLER 28. WASHER
4. CLAMP 16. CLAMP 29. CAPSCREW
5. HOSE 17. TUBE 30. FITTING
6. HOSE 18. WASHER 31. FAN SHROUD
7. TUBE 19. NUT 32. MAIN BAFFLE PLATE
8. STRAP CLAMP 20. HOSE 33. HOSE
9. WASHER 21. CLAMP 34. TUBE
10. WASHER 22. FITTING 35. HOSE
11. NUT 23. HOSE 36. RADIATOR
12. TIE ROD 24. LH BAFFLE PLATE 37. GROMMET
13. ISOLATOR 25. RH BAFFLE PLATE 38. CAPSCREW

Figure 7. Cooling System

11
Radiator Repair
3. Remove the support rods from the transmission
oil cooler.
4. Disconnect the transmission oil cooler from the
radiator.
WARNING
The transmission oil cooler is very heavy. At-
tach a lifting device capable of supporting the
transmission oil cooler.
5. Remove the transmission oil cooler from the en-
gine compartment.
Radiator Repair
REMOVE
1. Remove the noise baffles from beneath the en-
gine. See Figure 7.
2. Disconnect the lower coolant hose, and drain the
coolant from the radiator and engine.
3. Disconnect the upper coolant hose and the
coolant over flow tank hoses from the radiator.
4. Disconnect the fan shroud from the upper baffle,
and move the fan shroud toward the engine.
5. Remove the two lower baffles from the radiator.
6. Disconnect the upper baffle from the radiator
and move the upper baffle toward the engine.
7. Disconnect the transmission oil cooler from the
radiator.
WARNING
The radiator weighs 200 kg (441 lb). Attach a
lifting device capable of supporting the radia-
tor.
8. Remove the radiator from the engine compart-
ment.
12
100 SRM 631
INSTALL
WARNING
The transmission oil cooler is very heavy. At-
tach a lifting device capable of supporting the
transmission oil cooler.
1. Install the transmission oil cooler into the engine
compartment.
2. Attach the transmission oil cooler to the radiator.
3. Attach the support rods to the transmission oil
cooler.
4. Connect the transmission oil hose to the trans-
mission oil cooler.
5. Install the air intake tube onto the air cleaner
and the turbocharger.
INSTALL
WARNING
The radiator weighs 200 kg (441 lb). Attach a
lifting device capable of supporting the radia-
tor.
1. Install the radiator into the engine compartment.
2. Connect the main baffle plate to the radiator.
3. Install the left and right baffle plates onto the
radiator.
4. Connect the fan shroud to the upper baffle.
5. Connect the upper coolant hose and the coolant
over flow/fill tank hoses to the radiator.
6. Connect the lower coolant hose to the engine.
7. Connect the radiator to the transmission oil
cooler.
8. Install the noise baffles beneath the engine.
9. Fill the cooling system. See the section Periodic
Maintenance, ReachStacker 8000 SRM 592.
100 SRM 631 Exhaust System

Exhaust System
REMOVE 4. Remove the flexible exhaust tubes and elbows
from the turbocharger.
1. Remove the exhaust shield from the frame. See
Figure 8. 5. Remove the exhaust tube from the frame.

2. Remove the grille from the rear of the frame. INSTALL

3. Disconnect the exhaust tubes from the muffler, 1. Install the exhaust tube onto the frame.
and remove the muffler from the ReachStacker.

1. EXHAUST TUBE 10. GASKET 19. HEX HEAD BOLT

2. GASKET 11. BRACKET 20. BRACKET
3. BRACKET 12. ELBOW 21. EXHAUST TUBE
4. WASHER 13. EXHAUST TUBE 22. MUFFLER
5. HEX HEAD BOLT 14. WASHER 23. EXHAUST SHIELD
6. NUT 15. NUT 24. WASHER
7. HEX HEAD BOLT 16. ELBOW 25. HEX HEAD BOLT
8. GASKET 17. HEX HEAD BOLT 26. CAPSCREW
9. EXHAUST TUBE 18. HEX HEAD BOLT

Figure 8. Exhaust System

13
Engine Removal and Installation
2. Install the flexible exhaust tubes and elbows onto
the turbocharger.
3. Install the muffler into the ReachStacker and
connect the exhaust tubes to the muffler.
Engine Removal and Installation
REMOVE
Remove the Cummins M11 engine as follows:
WARNING
Make sure the battery disconnect switch is in
the off position before disconnecting or con-
necting cables.
WARNING
The boom must be supported at an 45 or
greater angle before beginning this procedure.
1. Disconnect the cables at the battery. (Remove the
ground cable first.)
2. Remove the right side handrail, and tilt the cab.
See Operator Compartment, Tilting.
3. Remove the hood and the front hood support.
4. Remove the three covers from the engine and
transmission compartments.
5. Remove the screens from under the Reach-
Stacker.
6. Remove the radiator and transmission oil cooler.
See Transmission Oil Cooler, Remove and Radi-
ator Repair, Remove.
7. Disconnect the exhaust system and air intake
systems from the turbocharger.
8. Disconnect the coolant reservoir hose from the
engine and drain coolant into a suitable con-
tainer.
9. Disconnect fuel lines at the fuel filter.
10. Disconnect hydraulic line from the slave cylinder
and drain hydraulic oil into a suitable container.
14
100 SRM 631
4. Install the grille onto the rear of the frame.
5. Install the exhaust shield onto the frame.
11. Disconnect wires and wiring harnesses at the en-
gine. Disconnect all remaining hoses at the en-
gine. Use a pan to catch the fluids that are in the
lines. Put tags on the wires, wiring harnesses,
and hoses for identification.
12. Disconnect the hydraulic oil lines at the hy-
draulic pumps. Use a pan to catch the oil that
is in the lines. Put tags on the lines and tubes
for identification. Put caps on the open lines and
the fittings.
13. Disconnect the wires and transmission fluid lines
at the transmission. Use a pan to catch the oil
that is in the lines. Put tags on the lines and
wires for identification. Put caps on the open
lines and the fittings.
14. Disconnect the drive shaft at the transmission.
15. Install a eyebolt into the engine end of the trans-
mission, and attach a lifting device capable of lift-
ing the engine transmission assembly to the for-
ward engine lift point and the eyebolt installed
into the transmission.
16. Remove the capscrews that hold the engine
mount at the fan end of the engine to the frame.
17. Remove the mounting brackets for the engine
and transmission from the ReachStacker.
18. Carefully lift the engine from the frame. Make
sure all the connections have been removed. Tag
any connections not previously disconnected for
identification.
INSTALL
1. Carefully lift the engine into the frame.
2. Install the mounting brackets for the engine and
transmission into the ReachStacker.
100 SRM 631
3. Install the capscrews that hold the engine mount
at the fan end of the engine to the frame.
4. Remove the lifting device from the forward en-
gine lift point and the eyebolt installed into the
transmission, and remove the eyebolt from the
transmission.
5. Connect the drive shaft to the transmission.
6. Connect the wires and transmission fluid lines to
the transmission as tagged during removal.
7. Connect the hydraulic oil lines to the hydraulic
pumps as tagged during removal.
8. Connect wires and wiring harnesses to the en-
gine as tagged during removal.
9. Connect fuel lines to the fuel filter.
10. Connect the coolant reservoir hose to the engine.
Operator Compartment
GENERAL
The operator’s compartment is a fully enclosed cab.
The operator’s compartment has doors, windows,
window wipers, and a heater system. The oper-
ator’s compartment includes the steering wheel,
instrument panel, Kruger load moment system,
transmission and brake system controls, attachment
controls, and the seat. The operator’s compartment
is installed on a platform and support base above
the main frame. Stairways and walkways on both
sides of the ReachStacker give access to the operator
compartment. The operator’s compartment is a
separate module from the frame of the ReachStacker
and can be removed as a complete unit.
TILTING
1. Raise the boom to a 30 angle and remove the two
bolts from the floor at the rear of the cab. See
Figure 9.
Operator Compartment
11. Connect the exhaust system and air intake sys-
tems to the turbocharger.
12. Install the radiator and transmission oil cooler.
See Transmission Oil Cooler, Install and Radia-
tor Repair, Install.
13. Connect all remaining hoses to the engine as
tagged during removal.
14. Install the screens under the ReachStacker.
15. Connect the cables to the battery, and start the
engine. Check for leaks.
16. Install the three covers from the engine and
transmission compartments.
17. Install the front hood support and the hood.
18. Lower the cab and install the right side handrail.
2. Remove the handle from the access door on the
right side of the vehicle and insert it into the cab
hydraulic pump located in the brake system com-
partment.
3. Move the direction control handle on the pump to
the left, and tilt the cab. See Figure 10.
LOWERING
1. Move the direction control handle on the pump to
the right, and lower the cab. See Figure 10.
2. Remove the handle from the cab hydraulic pump
located in the brake system compartment and in-
sert it into the access door on the right side of the
vehicle.
3. Install the two bolts into the floor at the rear of
the cab and lower the boom See Figure 10.
15
Operator Compartment
1. CAB HOLD DOWN BOLT AND WASHER (2)
2. CAB TILT HYDRAULIC CYLINDER
Figure 9. Cab in Tilted Position
REMOVE
NOTE: The operator’s compartment may be removed
from either side of the ReachStacker.
1. Remove the handrail from the walkway. See Fig-
ure 9 and Figure 11.
16
100 SRM 631
3. FORWARD CAB TILT POINTS
4. CAB
2. Tilt the operator’s compartment, and disconnect
all electrical cables and hydraulic hoses. Use a
pan to catch the fluid that is in the lines. Put
tags on the lines and electrical cables for identi-
fication. Put caps on the open lines and the fit-
tings.
100 SRM 631 Operator Compartment

Figure 11. Hydraulic and Electrical

Connections Under the Cab

WARNING
Make sure that the lifting device has the capac-
ity to lift a minimum of 768 kg (1697 lb).
1. HANDLE 3. DIRECTION
2. TILT PUMP CONTROL 5. Connect the lifting device to the lifting eyes, and
HANDLE remove all slack.

Figure 10. Cab Tilt Pump and Handle
3. Disconnect the hoses at the heater.
4. Install a lifting eye bolt on each side of the oper-
ator’s compartment roof.
6. Disconnect the rod end of the tilt cylinder from
the operator’s compartment.
7. Lower the operator’s compartment, and remove
the attaching hardware from the front mounts of
the operator compartment.

8. Carefully lift the operator’s compartment away

from the lift truck. Set the operator’s compart-
ment assembly in a suitable storage area, and
put blocks under the unit to make it secure and
stable.

17
Operator Compartment 100 SRM 631

INSTALL GAUGES AND SWITCHES

1. The gauges and switches in the operator’s com-
WARNING partment are fastened to removable panels. See
Make sure that the lifting device has the capac- Figure 12, Figure 13, and Figure 14. Remove
ity to lift a minimum of 768 kg (1697 lb). the screws that hold the panels to the instru-
ment panels. The electrical wiring diagrams are
1. Install a lifting eye bolt on each side of the op-
in the section Diagrams, ReachStacker 8000
erator compartment roof. See Figure 9 and Fig-
SRM 594. These diagrams will help identify the
ure 11.
wiring harnesses and components.
2. Connect the lifting device to the lifting eyes, and
2. See the section Instrument Panel Indicators
remove all slack.
and Senders 2200 SRM 143 to replace the
3. Lift the operator’s compartment into position on gauges.
the ReachStacker.
3. The rocker switches are replaced by pressing in
4. Install the attaching hardware into the front on the flexible tabs at the back side to release
mounts of the operator’s compartment. the switch assembly from the instrument panels.
The replacement switch is installed from the top
5. Connect the rod end of the tilt cylinder to the side of the instrument panel and pressed in until
operator’s compartment. the tabs on the switch lock in the opening for the
switch.
6. Connect the hoses to the heater.

7. Tilt the operator’s compartment, and connect all

electrical cables and hydraulic hoses as tagged
during removal.

8. Install the handrail onto the walkway.

18
100 SRM 631 Operator Compartment

NOTE: SEE THE OPERATOR’S MANUAL FOR THE DESCRIPTION OF THE USE AND OPERATION OF THE
LIGHTS, GAUGES, AND SWITCHES.
1. SPREADER INDICATOR LIGHTS (SEE 18. ENGINE OIL PRESSURE WARNING LIGHT
FIGURE 13) 19. PARKING BRAKE INDICATOR LIGHT
2. TOP WIPER SWITCH 20. ENGINE OVERSPEED LIGHT
3. REAR WIPER SWITCH 21. TURN SIGNAL INDICATOR
4. FRONT WINDSHIELD WIPER SWITCH 22. BATTERY DISCHARGE INDICATOR WARNING
5. KEY SWITCH LIGHT
6. PARKING BRAKE SWITCH 23. BRAKE OIL TEMPERATURE WARNING LIGHT
7. COOLANT TEMPERATURE GAUGE 24. START ENGINE AND INDICATOR LIGHT TEST
8. ENGINE OIL PRESSURE GAUGE 25. HIGH BEAM INDICATOR
9. FUEL GAUGE 26. EMERGENCY ENGINE STOP
10. VOLTMETER 27. INDICATOR FOR CHASSIS LIGHTS
11. HOURMETER 28. INDICATOR FOR BOOM LIGHTS
12. TACHOMETER 29. CHASSIS LIGHT SWITCH
13. HYDRAULIC OIL FILTER WARNING LIGHT 30. AIR FILTER RESTRICTION INDICATOR LIGHT
14. ENGINE COOLANT LEVEL WARNING LIGHT 31. BOOM LIGHT SWITCH
15. LOW BRAKE PRESSURE WARNING LIGHT 32. TRANSMISSION OIL FILTER WARNING LIGHT
16. TRANSMISSION OIL PRESSURE WARNING 33. BEACON LIGHT SWITCH
LIGHT 34. KRUGER OVERRIDE SWITCH
17. TRANSMISSION OIL TEMPERATURE WARNING
LIGHT

Figure 12. Gauges and Switches

19
Operator Compartment 100 SRM 631

NOTE: SEE THE OPERATOR’S MANUAL FOR THE DESCRIPTION OF THE USE AND OPERATION OF THE
LIGHTS, GAUGES, AND SWITCHES.
1. ROTATOR OVERRIDE WARNING LIGHT
2. KRUGER OVERRIDE WARNING LIGHT
3. GREEN INDICATOR LIGHTS, FRONT LEGS
POSITION*
4. AMBER INDICATOR LIGHTS, FRONT LEGS
POSITION*
5. BLUE INDICATOR LIGHTS*
6. AMBER INDICATOR LIGHTS
7. BLUE INDICATOR LIGHTS, TWIST LOCK
OPERATION
8. ATTACHMENT EMERGENCY STOP SWITCH
9. SELECTOR BUTTON, 35 FOOT CONTAINERS
(OPTIONAL)
10. OVERRIDE BUTTON (BOOM HOIST LOCK-OUT)
11. TWO-POSITION SWITCH (AUTO MANUAL)
12. ROTATOR OVERRIDE SWITCH
13. SELECTOR BUTTON, 30 FOOT CONTAINERS
(OPTIONAL)
14. SELECTOR BUTTON, 20 FOOT CONTAINERS
15. SELECTOR BUTTON, 40 FOOT CONTAINERS
16. TWIST LOCK BUTTON, RELEASE
17. TWIST LOCK BUTTON, ENGAGE

*AVAILABLE WITH BOTTOM PICK TYPE OF ATTACHMENT ONLY

Figure 13. Spreader Indicator Lights and Controls

20
100 SRM 631 Operator Compartment

NOTE: SEE THE OPERATOR’S MANUAL FOR THE DESCRIPTION OF THE USE AND OPERATION OF THE
LIGHTS, GAUGES, AND SWITCHES.
1. DISPLAY SCREEN 9. NOT USED
2. BOOM ANGLE 10. ANGLE PRESET BUTTON (WHITE)
3. BOOM LENGTH 11. TARE BUTTON
4. LOAD RADIUS/BOOM HEIGHT 12. NOT USED
5. ACTUAL LOAD 13. LOAD MOMENT METER
6. MAXIMUM LOAD 14. RED LIGHT BUTTON
7. NOT USED 15. YELLOW LIGHT BUTTON
8. NOT USED 16. GREEN LIGHT BUTTON

Figure 14. Load Sensing System

21
Window Wipers 100 SRM 631

Window Wipers
Two window wiper motor assemblies are installed in
the operator compartment. See Figure 15. The third
is installed on the back of the operator’s compart-
ment. The front window motor assembly has two
wiper arms connected to a single wiper blade. The
rear window and the top (overhead) window have
wiper motor assemblies that have one wiper arm at-
tached to a single wiper blade.

A. WINDSHIELD WIPER C. TOP WINDOW WIPER

B. REAR WINDOW WIPER
1. THREADED SHAFT TUBE 3. WIRE HARNESS
2. MOTOR

Figure 15. Window Wipers

22
100 SRM 631
SINGLE ARM UNIT (REAR WINDOW)
Remove
1. Remove the arm and the blade assembly from the
shaft.
2. Remove the nut and washers from the threaded
shaft tube that passes through the metal frame
of the operator’s compartment.
3. Remove the mounting screws from the single arm
wiper motor. Disconnect the electrical wire.
Install
1. Connect the electrical wire, and install the wind-
shield wiper motor into the mounting bracket
and install the mounting screws.
2. Install the nut and washers onto the threaded
shaft tube that passes through the metal frame
of the operator’s compartment.
3. Install the arm and the blade assembly onto the
shaft.
SINGLE ARM UNIT (TOP WINDOW)
Remove
1. Remove the arm and the blade assembly from the
shaft.
2. Remove the wiper motor box from the operator’s
compartment.
3. Remove the nut and washers from the threaded
shaft tube that passes through the metal frame
of the wiper motor box.
4. Remove the mounting screws from the single arm
wiper motor, and disconnect the electrical wire.
Window Wipers
Install
1. Connect the electrical wires, and install the sin-
gle arm wiper motor and the mounting screws.
2. Install the nut and washers onto the threaded
shaft tube that passes through the metal frame
of the wiper motor box.
3. Mount the wiper motor box onto the operator’s
compartment.
4. Install the arm and the blade assembly onto the
shaft.
DOUBLE ARM UNIT
Remove
1. Remove the arm and the blade assemblies from
the two outside shafts.
2. Remove the nuts and washers from the two
threaded shaft tubes that pass through the
metal frame of the operator’s compartment.
3. Disconnect the electrical wires.
4. Remove the front window wiper motor from the
mounting bracket.
Install
1. Install the front window wiper motor onto the
mounting bracket.
2. Connect the electrical wires.
3. Install the nuts and washers on the two threaded
shaft tubes that pass through the metal frame of
the operator’s compartment.
4. Install the arm and the blade assemblies on the
two outside shafts.
23
Heater Assembly 100 SRM 631

Window Washer Motor/Pumps

REMOVE
1. Disconnect the electrical cable from the reservoir
connector. See Figure 16.

2. Disconnect the three supply hoses located at the

bottom of the reservoir from the motor pumps.

3. Remove the washer reservoir from its mounting.

INSTALL
1. Install the washer reservoir into its mounting.

2. Connect the three supply hoses to the motor

pumps at the bottom of the reservoir.

3. Connect the electrical cable to the reservoir con-

nector.

1. MOTOR/PUMP 3. BRACKET
2. RESERVOIR 4. WIRING HARNESS

Figure 16. Window Washer System

Heater Assembly
REMOVE INSTALL
1. Disconnect the heater control cable from the wa- 1. Install the heater into the bracket, and tighten
ter control valve. See Figure 17. the knobs on both sides.

2. Disconnect the heater hoses from the rear of the
heater assembly.
3. Disconnect the air duct hoses and heater intake
from the heater.
4. Disconnect the heater wiring harness from the
heater.
5. Loosen the knobs on both sides and remove the
heater from the bracket.
2. Connect the heater wiring harness to the heater.
3. Connect the air duct hoses and heater intake to
the heater.
4. Connect the heater hoses to the rear of the heater
assembly.
5. Connect the heater control cable to the water con-
trol valve.

24
100 SRM 631 Heater Assembly

1. HEATER 12. RESISTOR 24. HEX HEAD BOLT

2. HOUSING (OUTLET) 13. HOSE (AIR DUCT) 25. HEX HEAD BOLT
3. HOUSING (HEATER 14. HOSE (HEATER) 26. NUT
CONTROL) 15. AIR INTAKE 27. NUT
4. SWITCH 16. HEATER INTAKE ELBOW 28. WASHER
5. KNOB 17. REDUCER 29. WASHER
6. WASHER 18. HOSE (AIR DUCT) 30. WASHER
7. LEVER 19. HOSE (HEATER) 31. RIVET
8. SUPPORT (CABLE) 20. HOSE (HEATER) 32. CLAMPS
9. CABLE (HEATER CONTROL) 21. HOSE (HEATER) 33. HOUSING (OUTLET)
10. WATER CONTROL VALVE 22. HOSE (HEATER) 34. GUARD
11. SPRING 23. HEX HEAD BOLT 35. SUPPORT BRACKET

Figure 17. Heater System

25
Door Handle Assembly 100 SRM 631

Door Handle Assembly

The door handle assemblies are made up of three
components; an outside handle with lock, an in-
side lever-type handle and latch mechanism, and a
striker. See Figure 18.

REMOVE
1. Remove the capscrew from the door handle lo-
cated inside of the door to remove the outside
handle.

2. Remove two capscrews to remove the inside door

handle.

INSTALL
1. Install the inside door handle and two capscrews.

2. To install the outside handle, install the cap-

screw through the inside door handle.

1. OUTSIDE HANDLE 3. INSIDE HANDLE

2. DOOR 4. CAPSCREW

Figure 18. Door Handle Assembly

26
100 SRM 631
Window Replacement
The front and rear windows will be replaced as single
units held in the window openings by a rubber seal
and locking strip.
WINDSHIELD
Remove
1. Remove the overhead window and cross bar from
the operator’s compartment.
2. Remove the locking strip from the seal, and re-
move the windshield from the seal.
3. If the seal is damaged, remove the seal from the
operator’s compartment window opening.
Install
1. If the rubber seal was damaged, install the new
rubber seal into the window opening.
CAUTION
Use a glass installation tool and a small putty
knife with edges that are not sharp and avoid
breaking the glass. Use these tools between the
glass and the rubber seal.
NOTE: Make sure the glass is dry, clean, and free of
grease.
2. Install the windshield into the rubber seal, and
make sure the seal is flat against the window and
the frame.
3. Install the locking strip into the rubber seal.
4. Install the cross bar and top window onto the op-
erator’s compartment.
REAR WINDOW
Remove
1. Remove the top window wiper enclosure.
Window Replacement
2. Remove the locking strip from the window seal.
3. Apply pressure to one edge of the window from
inside of the operator’s compartment, and using
a windshield pick, lift and remove the window
glass from the rubber seal.
4. Remove the rubber seal if it has been damaged.
Install
1. If the rubber seal has not been damaged, clean
thoroughly to remove all foreign matter.
2. Coat the channel of the seal with soap and water
solution.
3. Install the window into the rubber seal as far as it
will go without being forced, and using a window
pick alternating between the top and the bottom
of the window, work the rubber seal over the edge
of the window.
4. Install the locking strip into the window seal.
5. If the seal was damaged, install a new seal onto
the window frame of the operator’s compartment.
6. Apply sealing compound where the two ends of
the seal meet, and perform Step 1 through Step 3.
TOP WINDOW
Remove
Remove the window from the top of the operator’s
compartment, and remove all adhesive sealant from
the outside perimeter of the window, the window
opening, and the cross bar.
Install
Use the adhesive sealant on the window opening and
the top of the cross bar. Lower the window onto the
adhesive and fasten it at the front and rear with the
attaching hardware.
27
Label Replacement
Operator Restraint System
The seat belt, seat, and mounting are all part of the
operator restraint system. Each part must be in-
spected to make sure the attachment points are fas-
tened correctly and that the part operates correctly
and is in good condition.
The seat belt must fasten correctly. Make sure the
seat belt can be pulled from the retractor, retracts
Label Replacement
WARNING
If labels that have warnings or cautions are
damaged, they must be replaced.
The nameplate information is a safety item and must
be correct. See Figure 19.
1. Make sure the surface is dry and has no oil or
grease. Do not use solvent on new paint. Clean
the surface of old paint using a cleaning solvent.
28
100 SRM 631
smoothly, and is not worn or damaged. If the seat belt
cannot be pulled from the retractor assembly, replace
the seat belt.
Make sure the seat is fastened correctly at the at-
tachment points. The seat must lock in position on
the seat rails, but the seat must slide freely when it
is unlocked.
2. Remove the paper from the back of the label. Do
not touch the adhesive surface.
3. Carefully hold the label in the correct position
above the surface. The label cannot be moved
after it touches the surface. Put the label on the
surface. Make sure all air is removed from under
the label and the corners and edges are tight.
If the decals or information plates are missing or
damaged, they must be replaced.
100 SRM 631 Label Replacement

NOTE: THIS IS A PARTIAL LIST OF THE LABELS FOR THIS VEHICLE.

1. OPERATION WARNING 7. BATTERY DISCONNECT LABEL
2. WINDOW MATERIAL WARNING 8. REPLACE OPERATING MANUAL LABEL
3. ETHER WARNING 9. PARKING BRAKE LABEL
4. FAN WARNING 10. DOOR RELEASE LABEL
5. TIPOVER WARNING 11. DOOR RELEASE LABEL
6. NOTICE TO USER 12. ENGINE SHUT OFF WARNING

Figure 19. Warning and Safety Labels

29
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 TECHNICAL PUBLICATIONS

100 SRM 631 3/05 (9/97) Printed in United Kingdom