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©2016 HYSTER COMPANY

TABLE OF CONTENTS

General .....................................................................................................................................................................1
Safety Procedures When Working Near Mast .......................................................................................................1
Description ...............................................................................................................................................................2
Repair - General ...................................................................................................................................................... 4
Load Backrest ..........................................................................................................................................................4

Remove ................................................................................................................................................................ 4
Install ...................................................................................................................................................................4

Forks ........................................................................................................................................................................ 4

Replacement ........................................................................................................................................................4

Remove ............................................................................................................................................................ 5
Install .............................................................................................................................................................. 5

Reach Carriage Assembly ....................................................................................................................................... 5

Remove ................................................................................................................................................................ 5
Inspect ................................................................................................................................................................. 7
Install ...................................................................................................................................................................7

Reach Carriage Assembly Repair ...........................................................................................................................9
Load Rollers Repair ...............................................................................................................................................10
Side Rollers Repair (6.9 Mast Only) (N30ZDRS and N35-40ZRS)...................................................................... 11
Reach Assembly Front Frame .............................................................................................................................. 11

Remove .............................................................................................................................................................. 11
Disassemble (With Sideshift) ........................................................................................................................... 12
Disassemble (Without Sideshift) ......................................................................................................................14
Clean and Inspect ............................................................................................................................................. 15
Assemble (With Sideshift) ................................................................................................................................ 15
Assemble (Without Sideshift) ...........................................................................................................................15
Install .................................................................................................................................................................16

Single-Reach Scissor Arms ................................................................................................................................... 16

Remove and Disassemble ................................................................................................................................. 16
Clean and Inspect ............................................................................................................................................. 20
Assemble and Install ........................................................................................................................................ 20

Double-Reach Scissor Arms ..................................................................................................................................22

Disassemble .......................................................................................................................................................22
Clean and Inspect ............................................................................................................................................. 25
Assemble ............................................................................................................................................................25

Frame Assembly Rear............................................................................................................................................28

Remove .............................................................................................................................................................. 28
Disassemble .......................................................................................................................................................30
Clean and Inspect ............................................................................................................................................. 31
Assemble ............................................................................................................................................................31
Install .................................................................................................................................................................31

Reach Cylinders .....................................................................................................................................................32

Remove .............................................................................................................................................................. 32
Disassemble .......................................................................................................................................................34
Clean and Inspect ............................................................................................................................................. 35
Assemble ............................................................................................................................................................36
Install .................................................................................................................................................................36

Tilt Cylinder .......................................................................................................................................................... 37

Remove .............................................................................................................................................................. 37
Clean, Inspect, and Repair ............................................................................................................................... 37
Install .................................................................................................................................................................37

Table of Contents

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Summary of Contents for N30ZDR

Page 1: ...Hyster C264 N45ZR N35ZDR Forklift...

Page 2: ...REACH CARRIAGES N35ZDR N45ZR C264 N35ZDR2 N45ZR2 D264 N30ZDR N35 40ZR D470 N35 40ZR2 N30ZDR2 E470 N30ZDRS N35 40ZRS A265 N35 40ZRS2 N30ZDRS2 B265 PART NO 1590957 4500 SRM 1196...

Page 3: ...dic Maintenance section Keep the unit clean and the working area clean and orderly Use the correct tools for the job Keep the tools clean and in good condition Always use HYSTER APPROVED parts when ma...

Page 4: ...ove 11 Disassemble With Sideshift 12 Disassemble Without Sideshift 14 Clean and Inspect 15 Assemble With Sideshift 15 Assemble Without Sideshift 15 Install 16 Single Reach Scissor Arms 16 Remove and D...

Page 5: ...and Load Rollers 43 Adjust Reach Cylinders 44 Lift Chains 45 Inspect 45 Clean and Lubricate 46 Adjust Main Lift Chains 46 Adjust Free Lift Chains 46 Specifications 48 Troubleshooting 50 This section i...

Page 6: ...ore information Please click here Then get the complete manual NOTE If there is no response to click on the link above please download the PDF document first and then click on it Have any questions pl...

Page 7: ...less specifically authorized to do so Re pairs and adjustments must be performed by trained service technicians DO NOT climb on the mast or lift truck at any time Use a ladder or personnel lift to wor...

Page 8: ...has two sets of scissor arms for double reach See Figure 2 Both carriages have a tilt cylinder to tilt the forks Each carriage is available with sideshift function Refer to Figure 9 and Figure 10 The...

Page 9: ...E 2 TILT CYLINDER 3 REAR FRAME ASSEMBLY 4 REAR SELECTOR VALVE 5 SCISSOR ARMS 6 FRONT FRAME ASSEMBLY 7 FRONT SELECTOR VALVE 8 VALVE COVER PLATE 9 HOSE AND WIRING GUIDE 10 REACH CYLINDER Figure 2 Reach...

Page 10: ...ry to completely disassemble the reach carriage Do only the steps of the procedures necessary to make the required re pairs Read and follow the Safety Procedures When Work ing Near Mast in this sectio...

Page 11: ...r hook through the removal notch 1 FORK 2 BUTTON CAP 3 LATCH PIN 4 SPRING 5 PIN Figure 3 Forks 4 Slide the fork on the carriage so both upper and lower hooks are engaged and the latch pin aligns with...

Page 12: ...ting plate on the rear frame 6 Safety chain the reach carriage assembly in place See Safety Procedures When Working Near Mast 7 Disconnect the lift chains from the reach car riage assembly a Remove th...

Page 13: ...ations and welding techniques will be provided upon approval to ensure the struc tural integrity and safety of the repair 3 Inspect all welds between the reach carriage as sembly side plates and the c...

Page 14: ...reusing chains make sure chains have been properly inspected cleaned and lubricated See Lift Chains 7 Reconnect the lift chains to anchors on reach carriage assembly as removed Install anchor pins and...

Page 15: ...in the same position as it is in the mast The rear frame must also be fas tened so it cannot move on the support The sup port must be strong enough to allow full exten sion of the reach carriage assem...

Page 16: ...5 1 SNAP RING 2 LOAD ROLLER 3 SPACER 4 STUB SHAFT Figure 5 Load Roller Assembly NOTE Lightly pry the load roller from the stub shaft if necessary See Figure 6 3 Remove the load roller from the stub sh...

Page 17: ...im packs wash ers and capscrews 5 Measure and adjust the side rollers as neces sary See Reach Assembly Adjustments 6 Install the reach carriage assembly to the mast Reach Assembly Front Frame REMOVE N...

Page 18: ...ble ties for replacement during installation Disconnect the sideshift cylinder hydraulics if equipped See Sideshift Cylinder Repair 4 Tag and disconnect the wire connectors from the hose guide 5 Conne...

Page 19: ...only if repair is neces sary See Tilt Cylinder 1 LUBE FITTING 2 WEAR STRIP 3 WEAR STRIP 4 RETAINER PLATE 5 LOCKWASHER 6 CAPSCREW 7 TILT CYLINDER 8 PIVOT PIN 9 BUSHING 10 FIXED FRAME 11 TRUNNION CAP 12...

Page 20: ...pivot pins 8 from each side of tilting frame 6 Remove tilting frame from fixed frame 7 Remove bushings from fixed frame 8 Remove tilt cylinder trunnion caps capscrews 5 and pin 4 9 Remove tilt cylinde...

Page 21: ...pair 5 Install bushings to fixed frame if removed 6 Position tilting frame to fixed frame Use a pry bar to align pivot pin holes 7 Install pivot pins 8 through tilting frame into fixed frame Secure u...

Page 22: ...pivot pins that retain the inner scissor arms to the front frame 3 Install the brackets and hardware to retain the pivot pins NOTE The reach carriage assembly must be in stalled on the mast before st...

Page 23: ...12 SETSCREW 13 JAM NUT 14 LOAD ROLLER AND SHIMS 15 INNER SCISSOR ARM 16 BUSHING 17 BUSHING 18 PIVOT PIN 19 SHOULDER BOLT 20 PIN 21 PIN 22 NUT 23 90 HYDRAULIC FITTING 24 PIN 25 RH CYLINDER ASSEMBLY 26...

Page 24: ...s when removing the pivot pins Use a hammer and brass drift to remove the pins 4 Remove the shoulder bolt and nut from the reach cylinder pins Use a drift to drive out the cylinder rod end pins attach...

Page 25: ...Use a hammer and brass drift to remove the pivot pins 7 Models N35ZDR N45ZR N30ZDR and N35 40ZR have a position sensor mounted to the right side inner scissor arm pivot pin at the rear frame Remove th...

Page 26: ...stub shafts and all pins of the scissor arm assembly For the following procedures refer to Figure 11 WARNING Use safety chains on the rear frame and mast weldments to keep the rear frame and mast weld...

Page 27: ...lers on each outer scissor arm as marked during removal and disassembly Install snap rings onto stub shafts to secure See Figure 14 5 Use the crane to slowly raise the scissor arms to align the load r...

Page 28: ...ne to support scissor arm weldment A Securely attach chains or slings to the weld ment so that it cannot slip Be sure not to dam age the hose mount sheaves 4 Install the clamps and blocks at the chann...

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