Hyster A265 (N40ZRS) Forklift Service Repair Manual by 163114103

SERVICE REPAIR N35ZRS N40ZRS N30ZDRS [A265]

8000 SRM 1198

Oil Capacities

Lubrication Specifications Application

Lubrication Type

Standard

Cold Storage/Freezer

Arctic

Hydraulic Oil

ISO VG 46 Antiwear (HCE-140)

Exxon Univis® HVI 26

Grease

Multipurpose (Lithium Complex) Grease

Mobilgrease® 28 Synthetic Extra-Protection Grease

Gear Oil

80W-90 (GL-5) Conventional Gear Oil

75W-90 (GL-5) Synthetic Gear Oil

Antiseize

Antiseize Lubricant (MIL-A-706)

Oil Capacities Hydraulic System Truck Models

N30ZDR, N35ZDR, N35ZR, N40ZR, N45ZR

N30ZDRS, N35ZRS, N40ZRS

Battery Compartment Size

Tank (Full Capacity)

Usable Oil

368.0 mm (14.5 in.)

27.0 liter (28.5 qt)

19.6 liter (20.7 qt)

419.0 mm (16.5 in.)

27.0 liter (28.5 qt)

19.6 liter (20.7 qt)

470.0 mm (18.5 in.)

27.0 liter (28.5 qt)

19.6 liter (20.7 qt)

546.0 mm (21.5 in.)

30.7 liter (32.4 qt)

23.8 liter (25.1 qt)

368.0 mm (14.5 in.)

27.0 liter (28.5 qt)

19.6 liter (20.7 qt)

419.0 mm (16.5 in.)

27.0 liter (28.5 qt)

19.6 liter (20.7 qt)

Master Drive Unit Truck Models

Drive Type

Oil Capacity

N30ZDR, N35ZR, N40ZR, N30ZDRS, N35ZRS, N40ZRS

GK20 MDU

2.5 liter (2.6 qt)

N35ZDR, N45ZR

GK25 MDU

3.7 liter (3.9 qt)

Hydraulic System

8000 SRM 1198

Hydraulic System N30ZDR, N35ZDR, N35ZR, N40ZR, and N45ZR Motor

Pump Displacement

Speed (RPM)

Max Pump Pressure

36V

25.00cc

105 to 3300

20.68 MPa (3000 psi)

36V Hi Performance

28.00cc

105 to 3300

20.68 MPa (3000 psi)

36V - EE

20.00cc

105 to 3300

20.68 MPa (3000 psi)

24V/36V

2.08cc

600 to 3500

17.92 MPa (2600 psi)

Hydraulic System

Main Lift Pump and Motor

Auxiliary Pump and Motor

N30ZDRS, N35ZRS, and N40ZRS Hydraulic System

Motor

Pump Displacement

Speed (RPM)

Max Pump Pressure

24V

19.20cc

105 to 3300

20.68 MPa (3000 psi)

36V

19.20cc

105 to 3300

20.68 MPa (3000 psi)

Main Lift Pump and Motor

Relief Valves

Model

Valve Function

Relief Pressure 1

N30ZDR, N35ZDR, N35ZR, N40ZR, N45ZR

Main Lift Relief Valve Pressure

20.99 MPa (3045 psi)

Auxiliary Relief Valve Pressure

17.92 MPa (2600 psi)

N30ZDRS, N35ZRS, N40ZRS

Main Lift Relief Valve Pressure

17.24 MPa (2500 psi)

All measurements made when hydraulic oil temperature is 38 to 66 C (100 to 150 F).

8000 SRM 1198

Lift Specifications

Lift Specifications N30ZDR, N35ZDR, N35ZR, N40ZR, and N45ZR

Model

Voltage

N35ZR Lift Capacity 1588 kg (3500 lb)

N40ZR Standard Lift Capacity 1814 kg (4000 lb)

N40ZR High Performance Option Lift Capacity 1814 kg (4000 lb)

1 2

Amp Draw

Pressure (psi)

Lower Speed 2 (Ft/ Min)

Load

Lift Speed 1 (Ft/ Min)

Free Lift

Main Lift

Free Lift

Main Lift

100

245

365

4.48 MPa (650 psi)

5.86 MPa (850 psi)

907 kg (2000 lb)

1134 kg (2500 lb)

1361 kg (3000 lb)

1588 kg (3500 lb)

320

380

10.48 MPa (1520 psi)

13.20 MPa (1915 psi)

103

100

245

365

4.48 MPa (650 psi)

5.86 MPa (850 psi)

907 kg (2000 lb)

1361 kg (3000 lb)

1588 kg (3500 lb)

1814 kg (4000 lb)

320

380

11.41 MPa (1655 psi)

14.48 MPa (2100 psi)

103

115

375

480

5.52 MPa (800 psi)

8.62 MPa (1250 psi)

100

907 kg (2000 lb)

1134 kg (3000 lb)

1588 kg (3500 lb)

1814 kg (4000 lb)

480

530

11.38 MPa (1650 psi)

16.20 MPa (2350 psi)

105

Lift Speed Tolerance +3% and 10% Lower Speed Tolerance +5% and 10%

Lift Specifications

8000 SRM 1198

N30ZDR, N35ZDR, N35ZR, N40ZR, and N45ZR

Model

Voltage

N30ZDR Standard Lift Capacity 1361 kg (3000 lb)

N30ZDR High Performance Option

Lift Capacity 1361 kg (3000 lb)

N45ZR Standard Lift Capacity 2041 kg (4500 lb)

1 2

Load

Free Lift

Main Lift

Free Lift

Main Lift

100

245

365

4.48 MPa (650 psi)

5.86 MPa (850 psi)

907 kg (2000 lb)

1134 kg (2500 lb)

1361 kg (3000 lb)

320

380

10.48 MPa (1520 psi)

13.20 MPa (1915 psi)

103

115

375

480

5.52 MPa (800 psi)

8.62 MPa (1250 psi)

100

907 kg (2000 lb)

1134 kg (2500 lb)

1361 kg (3000 lb)

480

530

11.03 MPa (1600 psi)

15.86 MPa (2300 psi)

105

115

300

440

5.52 MPa (800 psi)

8.62 MPa (1250 psi)

105

907 kg (2000 lb)

1361 kg (3000 lb)

1588 kg (3500 lb)

1814 kg (4000 lb)

2041 kg (4500 lb)

500

540

11.38 MPa (1650 psi)

16.55 MPa (2400 psi)

105

Lift Speed Tolerance +3% and 10% Lower Speed Tolerance +5% and 10%

Amp Draw

Pressure (psi)

Lower Speed 2 (Ft/ Min)

Lift Speed 1 (Ft/ Min)

8000 SRM 1198

Lift Specifications

N30ZDR, N35ZDR, N35ZR, N40ZR, and N45ZR

Model

N45ZR High Performance Option

Voltage

Lift Capacity 2041 kg (4500 lb)

N35ZDR Standard Lift Capacity 1588 kg (3500 lb)

N35ZDR High Performance Option Lift Capacity 1588 kg (3500 lb)

1 2

Amp Draw

Pressure (psi)

Lower Speed 2 (Ft/ Min)

Load

Lift Speed 1 (Ft/ Min)

Free Lift

Main Lift

Free Lift

Main Lift

130

375

482

5.45 MPa (790 psi)

8.89 MPa (1290 psi)

105

907 kg (2000 lb)

1361 kg (3000 lb)

1588 kg (3500 lb)

1814 kg (4000 lb)

560

690

13.67 MPa (1982 psi)

18.44 MPa (2675 psi)

2041 kg (4500 lb)

14.48 MPa (2100 psi)

19.65 MPa (2850 psi)

105

115

307

440

4.94 MPa (717 psi)

8.53 MPa (1237 psi)

100

907 kg (2000 lb)

1134 kg (2500 lb)

1361 kg (3000 lb)

1588 kg (3500 lb)

500

540

11.27 MPa (1635 psi)

16.06 MPa (2330 psi)

105

130

5.17 MPa (750 psi)

8.62 MPa (1250 psi)

105

907 kg (2000 lb)

1134 kg (2500 lb)

1361 kg (3000 lb)

1588 kg (3500 lb)

11.38 MPa (1650 psi)

16.20 MPa (2350 psi)

105

Lift Speed Tolerance +3% and 10% Lower Speed Tolerance +5% and 10%

Lift Specifications

8000 SRM 1198

N30ZDRS, N35ZRS, and N40ZRS

Model

Voltage

N35ZRS Lift Capacity 1588 kg (3500 lb)

N40ZRS Lift Capacity 1814 kg (4000 lb)

N30ZDRS Lift Capacity 1361 kg (3000 lb)

N35ZRS Lift Capacity 1588 kg (3500 lb)

1 2

Load

Free Lift

Main Lift

Free Lift

Main Lift

323

329

2.76 MPa (400 psi)

4.14 MPa (600 psi)

1361 kg (3000 lb)

352

367

8.96 MPa (1300 psi)

11.03 MPa (1600 psi)

1588 kg (3500 lb)

353

374

9.65 MPa (1400 psi)

12.41 MPa (1800 psi)

100

323

329

2.76 MPa (400 psi)

4.14 MPa (600 psi)

1361 kg (3000 lb)

352

367

8.96 MPa (1300 psi)

11.03 MPa (1600 psi)

1588 kg (3500 lb)

353

374

9.65 MPa (1400 psi)

12.41 MPa (1800 psi)

100

1814 kg (4000 lb)

366

382

10.34 MPa (1500 psi)

13.10 MPa (1900 psi)

103

323

329

2.76 MPa (400 psi)

4.14 MPa (600 psi)

907 kg (2000 lb)

1134 kg (2500 lb)

1134 kg (3000 lb)

352

367

8.96 MPa (1300 psi)

11.03 MPa (1600 psi)

100

216

224

2.76 MPa (400 psi)

4.14 MPa (600 psi)

907 kg (2000 lb)

305

325

6.89 MPa (1000 psi)

9.65 MPa (1400 psi)

1361 kg (3000 lb)

318

330

8.96 MPa (1300 psi)

11.03 MPa (1600 psi)

1588 kg (3500 lb)

327

344

9.65 MPa (1400 psi)

12.41 MPa (1800 psi)

100

Lift Speed Tolerance +3% and 10% Lower Speed Tolerance +5% and 10%

Amp Draw

Pressure (psi)

Lower Speed 2 (Ft/ Min)

Lift Speed 1 (Ft/ Min)

8000 SRM 1198

Lift Specifications

N30ZDRS, N35ZRS, and N40ZRS

Model

Voltage

N40ZRS Lift Capacity 1814 kg (4000 lb)

N30ZDRS Lift Capacity 1361 kg (3000 lb)

1 2

Amp Draw

Pressure (psi)

Lower Speed 2 (Ft/ Min)

Load

Lift Speed 1 (Ft/ Min)

Free Lift

Main Lift

Free Lift

Main Lift

216

224

2.76 MPa (400 psi)

4.14 MPa (600 psi)

907 kg (2000 lb)

305

325

6.89 MPa (1000 psi)

9.65 MPa (1400 psi)

1361 kg (3000 lb)

318

330

8.96 MPa (1300 psi)

11.03 MPa (1600 psi)

1588 kg (3500 lb)

327

344

9.65 MPa (1400 psi)

12.41 MPa (1800 psi)

1814 kg (4000 lb)

341

352

10.34 MPa (1500 psi)

13.10 MPa (1900 psi)

103

216

244

2.76 MPa (400 psi)

4.14 MPa (600 psi)

907 kg (2000 lb)

1134 kg (2500 lb)

1361 kg (3000 lb)

318

330

8.96 MPa (1300 psi)

11.03 MPa (1600 psi)

100

Lift Speed Tolerance +3% and 10% Lower Speed Tolerance +5% and 10%

Torque Specifications

8000 SRM 1198

Tire Sizes Model

Drive (in.)

Caster (mm)

N30ZDR, N35ZR, N40ZR, N30ZDRS, N35ZRS, N40ZRS

12.5 × 5.5 × 8.0 Rubber

Load Wheels (in.) 5 × 3

200 × 50

12.5 × 5.5 × 8.0 Poly

5 × 3

13.5 × 5.5 × 8.0 Rubber N45ZR, N35ZDR

200 × 50

13.5 × 5.5 × 8.0 Poly

5 × 4

13.5 × 5.5 × 8.0 Siped Poly

5 × 4 6 × 4

Torque Specifications MASTER DRIVE UNIT Wheel Nuts 136 N•m (100 lbf ft) Use cross pattern to snug, half torque, then full torque. Apply antiseize to threads. Drive Unit to Frame Capscrews 95 N•m (70 lbf ft) Use cross pattern to snug, half torque, then full torque. Traction Motor to Drive Unit 23 N•m (17 lbf ft) Use cross pattern to snug, half torque, then full torque.

Scissor Arm Stud Castle Nuts (Double Reach Only) 115 N•m (85 lbf ft) Slightly loosen castle nut as necessary to align cotter pin holes. Reach Cylinder Rod End Capscrews 35 to 40 N•m (26 to 30 lbf ft) Tilt Cylinder Rod Nut 34 N•m (25 lbf ft) then back off 2 turns. Load Backrest 102 N•m (75 lbf ft)

MAST REACH CARRIAGE Center Bearing Retainer Capscrews Apply Loctite® 242 to capscrews and install into bearing cap along with belleville washers. Tighten to snug, then tighten each capscrew incrementally in a clockwise rotation to maintain even pressure the bearing. Capscrews are tight when belleville washers are flat.

Overhead Guard to Mast 149 N•m (110 lbf ft) Cylinder Bleed Screws 7 ±1 N•m (62 ±9 lbf in) Lower Mast Mounting Capscrews 203 N•m (150 lbf ft) Mast Trunnion Capscrews 210 N•m (155 lbf ft)

8000 SRM 1198

Fuses

HYDRAULIC SYSTEM (N30-35ZDR AND N35-40-45ZR)

Tank Plug (Top) 20 N•m (15 lbf ft)

Hydraulic Filter Cover 6 N•m (53 lbf in)

Tank Plug (Bottom) 67 N•m (50 lbf ft)

Hydraulic Filter Housing to Tank 8 N•m (72 lbf in)

Tank Plug (Top) 8 N•m (72 lbf in)

Breather Assembly to Tank 1.5 N•m (18.0 lbf in)

Pump Fittings 80 N•m (59 lbf ft) Tighten to touch, then 1/8th turn alternately until full torque.

Pump Pressure Flange 40 N•m (30 lbf ft) Tighten to touch, then 1/8th turn alternately until full torque. Lift Pump to Motor Mounting Capscrews 47 N•m (35 lbf ft) Tighten to touch, then 1/8th turn alternately until full torque.

HYDRAULIC SYSTEM (N30ZDRS AND N35-40ZRS) Hydraulic Filter Cover 6 N•m (53 lbf in) Hydraulic Filter Housing to Tank 8 N•m (72 lbf in)

Lift Pump to Motor Mounting Capscrews 61 N•m (45 lbf ft) Tighten to touch, then 1/8th turn alternately until full torque.

STEERING SYSTEM Steer Motor Mounting Capscrews 23 N•m (17 lbf ft)

LOAD WHEELS Load Wheel Axle Bolt 68 N•m (50 lbf ft) Apply antiseize to axles on nongreaseable load wheel assemblies.

Breather Assembly to Tank 1.5 N•m (18.0 lbf in)

Fuses Fuse

Circuit

Rating

FU 10

Key Switch Input

10 Amp

FU 11

24-Volt Supply

10 Amp

FU 12

12-Volt Supply

10 Amp

FU 13

Input to Controllers

10 Amp

FU 14

Spare

10 Amp

FU JP2

Voltage Regulator

7.5 Amp

Coil Resistance Values

8000 SRM 1198

Coil Resistance Values Coil

Location

Resistance

Test Points

Control Compartment

32.0 ±4.0 ohms

Coil Leads

Hydraulic Pump

40.0 ±5.0 ohms

Coil Leads

Tilt Selector

Attachment

40.0 ±5.0 ohms

Coil Leads

Sideshift

Attachment

40.0 ±5.0 ohms

Coil Leads

Auxiliary Straight

Attachment

40.0 ±5.0 ohms

Coil Leads

Auxiliary Reverse

Attachment

40.0 ±5.0 ohms

Coil Leads

Extend/Retract

Attachment

40.0 ±5.0 ohms

Coil Leads

Traction Motor

11.9 ±1.0 ohms

Coil Leads

Under Front Panel (LH) Drive Unit Door (Optional)

2.2 ±0.5 milliohms

Connector Pins

Main Contactor Load Hold

Brake Electrical Cooling Fan(s)

Traction Motor Windings Winding to Line Resistance (milliohm)

Voltage

Min

Max

3.22

3.83

3.22

3.83

Hydraulic Motor Windings Pump Displacement

Voltage

19.2cc

Winding to Line Resistance (milliohm) Min

Max

24 to 36

2.27

2.70

25.0cc

2.55

3.03

25.0cc

2.27

2.70

28.0cc

1.19

1.37

20.0cc

36 (EE)

2.27

2.70

8000 SRM 1198

Battery Specifications

Battery Specifications Battery Compartment Minimum Clearance 1

Model

N30ZDRS, N35ZRS, N40ZRS

N30ZDR, N35ZR, N40ZR, N30ZDRS, N35ZRS, N40ZRS

N45ZR, N35ZDR

24V

36V

Maximum Battery Dimensions 1

Length

Width

Length

Width

986.0 mm (38.8 in.)

318.0 mm (12.5 in.)

986.0 mm (38.8 in.)

311.0 mm (12.3 in.)

986.0 mm (38.8 in.)

371.0 mm (14.6 in.)

986.0 mm (38.8 in.)

365 mm (14.4 in.)

986.0 mm (38.8 in.)

422.0 mm (16.6 in.)

986.0 mm (38.8 in.)

416.0 mm (16.4 in.)

986.0 mm (38.8 in.)

371.0 mm (14.6 in.)

986.0 mm (38.8 in.)

365.0 mm (14.4 in.)

986.0 mm (38.8 in.)

422.0 mm (16.6 in.)

986.0 mm (38.8 in.)

416.0 mm (16.4 in.)

986.0 mm (38.8 in.)

422.0 mm (16.6 in.)

986.0 mm (38.8 in.)

416.0 mm (16.4 in.)

986.0 mm (38.8 in.)

478.0 mm (18.8 in.)

986.0 mm (38.8 in.)

473.0 mm (18.6 in.)

986.0 mm (38.8 in.)

536.0 mm (21.1 in.)

986.0 mm (38.8 in.)

530.0 mm (20.9 in.)

Battery Maximum Height (All Models) 787.0 mm (31.0 in.) 1

Battery measurements refer to length as the dimension between battery retainer plates on either side of the lift truck. Width refers to the most narrow dimension of the battery.

Battery Weight

Model

N30ZDRS, N35ZRS, N40ZRS

N30ZDR, N35ZR, N40ZR, N30ZDRS, N35ZRS, N40ZRS

N45ZR, N35ZDR

24V

36V

Min

Max

635 kg (1400 lb)

862 kg (1900 lb)

703 kg (1550 lb)

953 kg (2100 lb)

771 kg (1700 lb)

1032 kg (2275 lb)

703 kg (1550 lb)

953 kg (2100 lb)

771 kg (1700 lb)

1089 kg (2400 lb)

771 kg (1700 lb)

1089 kg (2400 lb)

998 kg (2200 lb)

1293 kg (2850 lb)

1134 kg (2500 lb)

1361 kg (3000 lb)

1800 SRM 1188

Introduction

Introduction GENERAL This section contains the description and replacement procedures for the spring applied, electrically-released parking brake. Some parts associated with the brake system are not covered in this section because they are more closely associated with other systems. See the section Electrical System 2200 SRM 1191 for information on parking brake wiring and the brake foot switch. Throughout this section, forward will refer to travel in the direction of the forks and left and right determined by an operator standing in the operator compartment facing the forks. See Figure 1.

immediately. If repair is necessary, attach a DO NOT OPERATE tag on the steering wheel. Remove the key from the key switch. Disconnect the battery before opening the electrical compartment covers or inspecting or repairing the electrical system. If a tool causes a short circuit, the high current flow from the battery can cause personal injury or property damage. Some checks and adjustments are done with the battery connected. DO NOT connect the battery until the procedure tells you to do so. Never have any metal on your fingers, arms, or neck. Metal items can accidentally make an electrical connection and cause injury. Before performing any tests or adjustments, block the lift truck to prevent unexpected movement. The capacitor in the transistor controller(s) can hold an electrical charge after the battery is disconnected. To prevent an electrical shock and personal injury, discharge the capacitor(s) before inspecting or repairing any component in the electrical compartments. Wear safety glasses. Make certain that the battery has been disconnected.

A. LEFT SIDE B. RIGHT SIDE C. FORWARD TRAVEL Figure 1. Truck Orientation

DISCHARGING THE CAPACITORS When working with the electrical systems of the truck, it is necessary to discharge the capacitors of the controllers associated with each circuit affected.

WARNING DO NOT make repairs or adjustments unless you have both authorization and training. Repairs and adjustments that are not correct can create dangerous operating conditions. DO NOT operate a lift truck that needs repairs. Report the need for repairs to your supervisor

DO NOT short across the motor controller terminals with a screwdriver or jumper wire.

CAUTION To avoid controller damage, always disconnect the battery, discharge the capacitor(s), and never put power to the controller while any power wires are disconnected. Never short any controller terminal or motor terminal to the battery. Make sure to use proper procedure when servicing the controller. 1. Move the lift truck to a safe, level area and completely lower the mast. Turn the key switch to the OFF position and attach a DO NOT OPERATE tag to the control handle. Block the drive wheel to prevent unexpected movement.

Electric Brake

1800 SRM 1188

2. Disconnect the battery power cable connector from the truck connector located on the right side of the frame. Pull the battery cable connector handle to separate the battery connector from the truck connector. 3. Remove the operator compartment cover. 4. Discharge the capacitor in the controllers by connecting a 200-ohm, 2-watt resistor across the controller B+ and B terminals of the motor controller. Remove the resistor after discharging the capacitors. See Figure 2.

1. 2. 3. 4.

POSITIVE CONNECTION (B+) NEGATIVE CONNECTION (B ) INSULATED JUMPER WIRES 200-OHM, 2-WATT RESISTOR Figure 2. Discharging the Capacitors

Electric Brake The electric brake is located in the drive unit compartment mounted to the top of the traction motor. It consists of a spring-applied, electrically-released brake mounted directly to the drive motor. See Figure 3. The electric brake is controlled by the master controller. After receiving input signals from the floor switches and a traction input from the multifunction control handle, the master controller will complete the circuit to the brake coil, releasing the brake. The master controller breaks the power supply to the brake coil, engaging the electric brake when the truck is stopped. Pressing the emergency disconnect will apply the electric brake immediately in any mode of operation. The electric brake may be manually released for towing by inserting two standard 1/4-20 Ă&#x2014; 1-1/4 in. capscrews into the two threaded holes in the top of the brake assembly. See Figure 4.

1. 2. 3. 4. 5. 6.

FRAME MAST TRUNNIONS BATTERY COMPARTMENT FLOOR MAT TRACTION MOTOR BRAKE ASSEMBLY Figure 3. Brake Location

1800 SRM 1188

Electric Brake 5. If the air gap is too tight for a minimum feeler gauge to enter any of the six locations, the air gap has been altered by internal damage or tampering. Replace the entire brake assembly. See Remove. NOTE: During brake operation, the brake should engage and release with a solid, single-click noise. A double-clicking noise indicates that one side of the brake is releasing before the other. 6. Listen to verify the brake releases and applies in one smooth operation. A double-clicking noise indicates that one side of the brake is releasing before the other due to internal damage or tampering. Replace the entire brake assembly. See Remove.

1. 2. 3. 4.

SERVICE CAPSCREWS SERVICE PORTS BRAKE ASSEMBLY ASSEMBLY HOLES Figure 4. Manual Release

AIR GAP CAUTION The brake is not adjustable. Check the air gap to determine if replacement is necessary. NOTE: The air gap is very thin and may not be checked visually. Dimensions are not to scale and are for location references only. 1. Check the three outer socket head screws for appropriate torque to secure the brake to the motor. 2. Check for correct air gap by measuring the distance between the bottom of the stator and the top of the pressure plate with the brake applied (disconnected) using feeler gauges. Air gap should measure 0.20 to 0.40 mm (0.008 to 0.015 in.). See Figure 5. 3. The air gap should be checked for minimum and maximum clearance at the six locations shown in Figure 6. 4. If the air gap allows the maximum feeler gauge to enter any of the six locations, replace the entire brake assembly. See Remove.

1. 2. 3. 4.

STATOR AIR GAP PRESSURE PLATE FEELER GAUGE Figure 5. Air Gap

Electric Brake

Figure 6. Check Locations (Typical Brake)

REMOVE The following procedures detail the removal and installation procedures for the electric brake. The brake assembly is nonadjustable and contains no service parts. If the brake fails to function, it must be replaced as a complete assembly. Check the electric brake before each shift for proper operation. Refer to Periodic Maintenance 8000 SRM 1197.

1800 SRM 1188

1. 2. 3. 4. 5. 6.

ELECTRIC BRAKE AND HUB CAPSCREW LOCKWASHER WASHER RETAINING RING WOODRUFF KEY Figure 7. Electric Brake

7. Remove the retaining ring securing the hub to the motor shaft. 8. Remove the hub from the motor shaft. Recover the Woodruff key.

INSTALL

1. Move the lift truck to a safe, level area and completely lower the mast. Turn the key switch to the OFF position and attach a DO NOT OPERATE tag to the control handle. Block the drive wheel to prevent unexpected movement. See Figure 7.

1. Install the Woodruff key to the motor shaft. Align the groove in the hub with the Woodruff key and Install the hub onto the motor shaft.

3. Position the brake assembly onto the hub. Align the brake mounting slots with the mounting holes in the motor housing (as removed) and secure using four capscrews, lockwashers, and washers. See Figure 7.

3. Open the drive unit compartment door.

4. Install brake wiring harness to the main wiring harness as removed.

4. Disconnect the electric brake wiring harness from the main wiring harness near the electric brake assembly. 5. Remove the four capscrews, lockwashers, and washers securing the brake assembly to the drive motor. 6. Lift the brake assembly up off the hub and the motor housing.

2. Install the retaining ring onto the motor shaft to secure the hub.

5. Connect the battery. Turn key switch to the ON position and listen for the electric brake to release. Check for proper operation. 6. Secure the drive unit compartment door closed. Remove the DO NOT OPERATE tag from the control handle and remove the blocks from drive wheel.

1800 SRM 1188

Troubleshooting

Troubleshooting PROBLEM Electric brake will not release.

POSSIBLE CAUSE

PROCEDURE OR ACTION

Key switch is in the OFF position.

Turn key switch to the ON position.

Battery is not connected or is discharged.

Connect or clean battery connections. Charge if necessary.

Wiring or controller malfunction(s).

Refer to wiring diagrams.

Excessive wear.

Replace the brake assembly.

Brake coil is defective.

Check brake coil resistance. Resistance should read 11.9 ohms Âą1.0 ohm. Replace brake assembly if necessary.

Foot switches not engaged or not working properly.

Check battery voltage at brake coil connector.

Multifunction handle not in FWD or REV position.

Set multifunction handle to FWD or REV position.

Electric brake will not apply.

Internal brake.

Replace the brake assembly.

Electric brake does not hold truck loaded to specification.

Oil or grease on the friction surfaces.

Replace the brake assembly.

Friction surfaces are worn out.

Replace the brake assembly.

Springs are too weak.

Replace the brake assembly.

Load exceeds truck capacity.

Handle only approved load weight.

Brake components worn or damaged.

Replace the brake assembly.

Brake coil defective.

Replace the brake assembly.

mechanical

damage

Troubleshooting

PROBLEM Brake drags or gets hot.

1800 SRM 1188

POSSIBLE CAUSE

PROCEDURE OR ACTION

Battery is discharged or connections are loose or dirty.

Clean battery connections. Charge if necessary.

Excessive wear.

Replace brake assembly.

Brake coil defective.

Check coil resistance. Resistance should read 11.9 ohms Âą1.0 ohm.

Oil or grease in brake.

Replace brake assembly.

Incorrect brake air gap.

Check air gap is within 0.007 to 0.015 inch. Replace brake assembly if gap is not within specification.

100 SRM 1185

Repairs - General

General from the perspective of an operator in the operator compartment facing the forks. See Figure 1.

WARNING DO NOT make repairs or adjustments unless you have been properly trained and specifically authorized to do so. Repairs and adjustments that are incorrect can create dangerous operating conditions. DO NOT operate a lift truck that needs repairs. Report the need for repairs to your supervisor immediately. If repair is necessary, disconnect the battery and attach a DO NOT OPERATE tag to the control handle. This section contains descriptions of the frame components, repair procedures, and assembly information. These components include the frame weldment, door, floor plate, and covers. The overhead guard and base arms are also covered in this section. Throughout this section, forward will refer to travel in the direction of the forks, and left and right will be

A. LEFT B. RIGHT

C. FORWARD

Figure 1. Travel Orientation

Description The frame is available in two sizes: small chassis and large chassis. The small chassis is used for the N30ZDR, N35-40ZR, N30ZDRS, and N35-40ZRS unit and uses a smaller drive unit. The small chassis frame is available with a 368.3 mm (14.5 in.) or 419.1 mm (16.5 in.) battery compartment width. The large chassis is used for the N35ZDR and N45ZR unit and uses a larger drive unit. The large chassis frame is available with a 419.1 mm (16.5 in.), 469.9 mm (18.5 in.), or 546.1 mm (21.5 in.) battery compartment width. The frame has mounts for the following parts: • Mast Assembly

• Steering System Parts • Electrical System Parts • Hydraulic System Parts • Door, Floor Plate, Access Panels, and Covers The overhead guard fastens to the mast. A rear operator guard leg provides protection for the operator and unobstructed operation of the lift truck. The operator guard leg fastens between the overhead guard and the frame. Repair procedures for major components that fasten to the frame are in separate sections. See each section for the system that has the part to be repaired.

Repairs - General Repair is seldom required on the frame unless the truck has been structurally damaged. Most truck repairs involve removing the system parts that attach to the frame. Refer to the appropriate section for the system that needs repair. To separate the mast from the frame, refer to the sections Mast, Repair 4000 SRM 1195 and Reach Carriages 4500 SRM 1196.

To replace the load wheels in the base arms, see the section Periodic Maintenance 8000 SRM 1197 or Load Wheels in this section. The caster wheel assembly is part of the steering assembly. See the section Steering System 1600 SRM 1187 to replace the caster wheel assembly or the caster wheels. To replace the drive wheels or tires, see the section Periodic Maintenance 8000 SRM 1197.

Covers, Panels, and Plates

100 SRM 1185

WELDING

the area to be welded. Use local ventilation, and/or supplied, air-respiratory protection.

WARNING Remove the battery and disconnect the battery connector before welding. Welding can cause a fire and/or an explosion. Make sure there is no oil or grease near the weld area and that the area is well-ventilated. Forklift truck frames and components may have polyurethane paint. Welding, burning, or other heat sufficient to cause thermal decomposition of the paint may release isocyanates. These chemicals are allergic sensitizers to the skin and respiratory tract irritants. Overexposure may occur without odor warning. When performing work, utilize good industrial hygiene practices, including removal of all paint (prime and finish coats) to the metal around

CAUTION Certain welding repairs require factory approval. Structural members such as base arms, axle weldments, and mast components require written Hyster engineering approval before repairing or replacing. Contact your local dealer for factory assistance.

CAUTION Connect the welding ground clamp as close to the weld area as possible to prevent welding current from straying. Only properly trained, authorized technicians should perform welding repairs.

Covers, Panels, and Plates FRONT FRAME PANEL (LEFT AND RIGHT) Remove the screws from the upper and lower ends of the front frame panel. Pull the lower end of the panel away from the frame of the lift truck and gently work up the side of the panel to pull it from the retainer clips securing the panel to the frame. Pull the top end tabs out of the operator compartment cover. Repeat for opposite side as necessary. See Figure 2. NOTE: On right-side, front frame panels, ensure the diagnostic connector cap is positioned correctly to allow the cover to seat properly. To install the panel, position the upper end of the panel partially into the retaining clip on the frame. Insert the tabs on the upper end of the panel into the slots in the operator compartment cover. Work the sides of the panel into the retaining clips until all areas of the panel are aligned with the frame. Align the holes in the panel with the mounting brackets on the frame and loosely install the screws into the upper end and lower end of the panel. Make certain the panel is seated correctly against the frame and tighten the screws to secure in place. See Figure 2. Figure 2. Front Frame Panel (Left Side)

100 SRM 1185

Covers, Panels, and Plates Legend for Figure 2

1. 2. 3. 4. 5. 6. 7. 8.

OPERATOR COMPARTMENT COVER FRAME LOWER BRACKET LOWER SCREW FRONT COVER PANEL (LEFT) TABS UPPER BRACKET UPPER SCREW

OPERATOR COMPARTMENT COVER Remove the front frame panels from the lift truck. See Front Frame Panel (Left and Right). Remove the two screws securing the operator cover to the frame brackets. One is located on the lower right side of the operator compartment above the operator presence switch. The other is located beside the overhead guard post mount, at the bottom of the cup holder. Pull the operator compartment cover up from the front right corner. Continue pulling the cover up along the edge of the frame in both directions until the cover is free from the retaining clips. See Figure 3.

To install, position the cover over the electrical compartment. Align the lip of the cover to the retaining clips. Press the lip of the cover into the retaining clips starting at the overhead guard post and continue around until completely seated. Align the holes in cover with the mounting brackets and install retaining screws as removed. Install the front frame panels to complete assembly. Refer to Front Frame Panel (Left and Right).

DRIVE UNIT COMPARTMENT DOOR Completely loosen the two socket head capscrews securing the drive unit compartment door closed. The screws are spring-loaded and are retained to the door by clips. Pull the door open on its hinges. To close, push the door closed and start both socket head capscrews loosely into the mounting holes. When both screws are started, verify that the door seats properly against the frame and tighten the screws.

DOOR PAD Open compartment door and remove the seven capscrews holding the pad to the door. Lift the pad over the steering mechanism and remove. To instal the pad, lower it over the steering mechanism and position it onto the door. Install the seven socket head capscrews as removed.

OPERATOR BACK PAD Side-Stance Models Remove the five socket head capscrews retaining pad to the adjuster mechanism and remove the pad. To install, position the back pad onto the adjuster mechanism and loosely install the five socket head capscrews as removed. Verify that the back pad seats properly to the adjuster mechanism and tighten to secure as removed.

Forward-Stance Models NOTE: On models with Aft Travel controls, guide the aft travel control handle wiring harness into/out of the frame when installing/removing the operator back pad. 1. 2. 3. 4.

OPERATOR COMPARTMENT COVER RETAINING SCREW FRAME FRONT COVER PANEL (LEFT) Figure 3. Operator Compartment Cover

Remove the operator compartment cover to access the screw securing the front of the operator back pad to the frame. Remove the two screws securing the operator back pad to the frame and remove the pad from the frame.

Load Wheels

100 SRM 1185

To install, position the back pad against the frame as removed. Install the two screws securing pad to frame as removed, and reinstall the operator compartment cover.

the frame. Align the pad bracket holes and install the screws to secure the pad in place. Install the operator compartment cover in place.

CASTER WHEEL COVER OPERATOR FRONT PAD Remove the operator compartment cover from the lift truck. See Operator Compartment Cover. Remove the screws securing the pad brackets to the frame. Pull the top of the pad away from the frame and then lift the pad from the lower retaining clips. To install, position the lower pad brackets into the retaining clips. Position the upper end of the pad to

Remove the two socket head capscrews on top of the caster wheel cover and lift cover from the clips securing it to the frame. To replace, fit the bottom of the cover into the clips inside the opening and slide the cover into place. Install two socket head capscrews to secure the top of the cover in place.

Load Wheels REMOVE Slightly raise the base arms and support on blocks as described in the Periodic Maintenance 8000 SRM 1197. Make sure the base arms and load wheels do not support any weight. 1. Remove the nut, washers, and axle bolt. See Figure 4. 2. Remove the load wheels from the hanger brackets.

3. Remove the axle sleeves and bearings from the load wheels. Check for wear or roughness as the bearings are rotated. Replace both bearings if wear or roughness is noted. Inspect the load wheels for damage or wear. Replace as necessary.

CAUTION Use a hammer and a soft punch when removing bearings to avoid damage to bearings and/or load wheel. 4. Remove the hanger bracket from the base arms and inspect thoroughly. Inspect the base arms thoroughly for damage.

INSTALL WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. Wear protection when handling solvents and always follow the recommendations of the manufacturer.

CAUTION 1. Clean all parts with solvent and inspect thoroughly. Replace damaged parts as necessary. 1. AXLE BOLT 2. WASHER 3. HANGER BRACKETS

4. 5. 6. 7.

AXLE SLEEVE BEARING LOAD WHEEL NUT

Figure 4. Load Wheels

2. Apply lithium grease to the pivot contact on the hanger brackets. Position the hanger brackets into the base arms and install the load wheels and axle sleeves into the hanger brackets. See Figure 5.

100 SRM 1185

Overhead Guard Replacement 3. Install the bearings into the load wheels. a. Sealed Bearings - Install the bearings into the load wheel assemblies. Position the axle sleeve into the assembly. Apply antiseize lubricant to the axle bolt.

1. 2. 3. 4.

b. Side-Shielded Bearings - Install one bearing into the load wheel with the shielded side facing out. Fill the cavity inside of the load wheel with grease. Install the other bearing into the load wheel with the shielded side facing out. Position the axle sleeve into the assembly.

PIVOT CONTACT HANGER BRACKET LOAD WHEELS BASE ARM Figure 5. Hanger Bracket Pivots

CAUTION The bearings are replaced by pressing on the outer race of the bearing only. Pressing or tapping on the inner race will damage the bearing. Use a suitable driver when installing bearings to avoid damage to bearings and/or load wheel. Replace bearings in sets to maintain proper wheel loading and operation. NOTE: Load wheel assemblies that have axle bolts equipped with lube fittings use side-shielded bearings and must be greased. Assemblies with axle bolts not equipped with lube fittings use sealed bearings and cannot be greased.

4. Apply grease to the pivot contact on the hanger brackets. Position the hanger brackets into the base arms and install the load wheels and axle sleeves into the hanger brackets. 5. Install a washer onto the axle bolt. Install the axle bolt through the hanger brackets, bearings, and axle sleeve with the threads to the inside of the base arms. 6. Install washers and nuts to the axle bolts. Torque to 68 Nâ&#x20AC;˘m (50 lbf ft). NOTE: If axle shafts are equipped with lube fittings, grease to fill load wheel cavity. Refer to Periodic Maintenance 8000 SRM 1197 for regularly scheduled maintenance procedures.

Overhead Guard Replacement WARNING DO NOT weld mounts for lights or accessories to the overhead guard. The strength of the overhead guard can be reduced by welding or heating. Install lights and accessories or their mounts with clamps. The strength of the overhead guard can be reduced if holes are drilled in the wrong location or are too large. Contact your lift truck dealer before welding or drilling holes in any part of the overhead guard.

The overhead guard assembly is heavy. Be sure that all lifting devices (hoists, cables, chains, slings, etc.) are suitable and of adequate capacity to lift the overhead guard. The overhead guard assembly consists of the overhead guard and a support post. See Figure 6 and Figure 7. The overhead guard is attached to the mast with six capscrews (2) and lockwashers (3). The top of the support post is bolted to the overhead guard. The bottom of the post fits into a retainer in the drive unit compartment.

Overhead Guard Replacement

Figure 6. Overhead Guard (N35ZDR, N45ZR, N30ZDR, N35-40ZR)

100 SRM 1185

Overhead Guard Replacement Legend for Figure 6

1. 2. 3. 4. 5.

OVERHEAD GUARD CAPSCREW LOCKWASHER PLUG (W/O HEAD LAMPS) CAPSCREW

The size of the overhead guard varies depending upon the battery compartment size.

6. 7. 8. 9.

CAPSCREW PLUG SUPPORT POST BUSHING

INSTALL

REMOVE

Refer to WARNING (above) before performing service to any overhead guard components.

1. Attach a suitable lifting device to the overhead guard.

2. Align the overhead guard with the top of the mast and install the six capscrews (2) and lockwashers (3). See Figure 6. Torque the capscrews to 149 Nâ&#x20AC;˘m (110 lbf ft).

2. Remove the two capscrews (6) retaining the support post to the overhead guard. See Figure 6. Pull the support post out of the retainer in the lift truck frame. Remove the support post.

3. Slide the support post into the retainer in the lift truck frame. Install the two capscrews (6) retaining the support post to the overhead guard.

3. Remove the six capscrews (2) and lockwashers (3) retaining the overhead guard to the mast. Lower the overhead guard to the floor.

Overhead Guard Replacement

Figure 7. Overhead Guard (N30ZDRS, N35-40ZRS)

100 SRM 1185

Overhead Guard Replacement Legend for Figure 7

1. 2. 3. 4.

OVERHEAD GUARD CAPSCREW LOCKWASHER PLUG (W/O HEAD LAMPS)

5. 6. 7. 8.

CAPSCREW CAPSCREW SUPPORT POST BUSHING

1. 2. 3. 4. 5.

BRACKET RETAINING CAPSCREW AND NUT SCREW LENS RETAINER LENS

FRONT LIGHTS Two front (head) lights are mounted by their brackets to the front of the overhead guard.

Bulb Replacement 1. Remove the four screws securing the lens retainer and lens to the assembly. Hold the lens in place until all screws have been removed then remove the lens and retainer. Replace as required. See Figure 8. 2. Remove the bulb from the fixture and replace with new.

CAUTION Overtightening the screws can break the lens. 3. Position the lens and the retainer to the fixture and install the four screws.

Figure 8. Lens Removal

Overhead Guard Replacement

100 SRM 1185

Assembly Replacement 1. Disconnect the wiring harness from the light assembly connector.

3. Remove the bracket from the overhead guard and replace, if necessary. 4. Install bracket to overhead guard, if removed.

2. Remove the nut and washers from the capscrew securing the headlight assembly to the bracket. Slide the capscrew from the bracket and remove the headlight. See Figure 9.

5. Position the light assembly to the bracket and install capscrew and attaching hardware. Tighten slightly to allow for adjustment.

1. 2. 3. 4.

5. 6. 7. 8.

ADJUSTMENT SLOT ADJUSTMENT BOLT OVERHEAD GUARD WIRING HARNESS

HEADLIGHT CONNECTOR WIRE CLAMP ATTACHING HARDWARE

Figure 9. Head Light Mounting

100 SRM 1185

Rear Work and Caution Light The rear work and caution lights are options that mount to the overhead guard near the rear of the truck. Several configurations of these assemblies are available and connect to the options harness. To repair the light assemblies, perform the following procedures. Some repairs may not require total disassembly. Perform only the steps necessary to safely complete the required service. See Figure 10.

Overhead Guard Replacement 8. Position the cage onto the studs of the light assembly. Install nuts and washers onto studs. 9. Remove blocks from the wheel and return to service.

The work light is very similar to the front light, except for its mounting platform and location. To repair or replace the work light, refer to the instructions for repairing or replacing the front lights. See Front Lights.

Caution Light 1. Move the lift truck to a safe, level area and completely lower the mast. Turn the key switch to the OFF position and attach a DO NOT OPERATE tag to the control handle. Block the drive wheel to prevent unexpected movement. 2. Disconnect the battery power cable connector from the truck connector located on the right side of the frame. Pull the battery cable connector handle to separate the battery connector from the truck connector. 3. Remove the nuts securing the cage to the light assembly. Remove the cage. 4. Remove the screws and washers securing the lens globe to the light assembly. Remove the lens globe. 5. Remove the bulb from the fixture and replace if necessary. 6. Connect the battery and turn the key switch to the ON position. Test for proper operation. 7. Position the lens globe to the light assembly. Install screws to secure.

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

CAGE GLOBE STUDS AND NUTS UPPER MOUNTING FLANGE LOWER MOUNTING FLANGE SCREW MOUNTING BRACKET WORK LIGHT WITH ADJUSTABLE BRACKET WORK LIGHT WIRING HARNESS STROBE WIRING HARNESS Figure 10. Rear and Caution Light

Painting Instructions

100 SRM 1185

Painting Instructions WARNING Some frames and components are painted with polyurethane paint. Welding, burning, or other heat sufficient to cause thermal decomposition of the paint may release isocyanates. These chemicals are allergic sensitizers to the skin and respiratory tract irritants. Overexposure may occur without odor warning. When heat must be applied, use good industrial hygiene practices, including removal of all paint (prime and finish coats) to the metal around the area to be heated. Use local ventilation, and/or supplied, air-respiratory protection. Cleaning solvents may be flammable and/or toxic and may cause skin irritation. Always wear proper eye and skin protection. Always use solvents and paints in an area with adequate ventilation. DO NOT use solvents or paints near heat, fire, or electrical equipment that can make sparks. Follow the paint manufacturerâ&#x20AC;&#x2122;s instructions and precautions.

CAUTION DO NOT put tape on cylinder rods to protect from paint. Use a thick layer of multipurpose grease to protect cylinder rods. Cylinders can be damaged if operated with tape on the cylinder rod. 1. Clean the surface to be painted. Use a solvent on surfaces to be painted to remove grease and oil before sanding. DO NOT use solvent to clean new paint. Make sure all oil and grease is removed.

2. Use sandpaper to remove the top surface of paint and rust from the metal. All metal surfaces where the paint has been removed to the bare metal must be primed. Apply primer BEFORE applying the paint. 3. Protect all surfaces that will not be painted. DO NOT paint: All Plastic Covers Steering Handle Dash Display Control Handles Labels and Information Plates Operator Pads Tires and Load Wheels Chains and Hoses Battery Connectors All Switches Cylinder Rods Pumps and Motors Wiring Harnesses or Connectors

CAUTION Protect electrical components, wiring, and electrical contacts from overspray. 4. Paint the surfaces using Hyster approved paints. Follow the proper paint scheme for your lift truck model (refer to the Parts Manual for specific information on paint for your lift truck). 5. Install new safety labels. See Safety Labels Replacement.

100 SRM 1185

Safety Labels Replacement

Safety Labels Replacement all air is removed from under the label or plate and the corners and edges are tight. DO NOT attempt to move the label or plate once it has been stuck down.

WARNING Safety labels are installed on the lift truck to give information about operation and possible hazards. It is important that all safety labels are installed on the lift truck and can be read. DO NOT add to or modify the lift truck. Any change to the lift truck, the tires, or its equipment can change the lifting capacity. The lift truck must be rated as equipped and the nameplate must show the new capacity rating. Contact your lift truck dealer for a replacement nameplate. Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the recommendations of the manufacturer. If an adhesive plate or label must be replaced, use the following procedure to install a new label or plate. See Figure 11 and Figure 12. 1. Clean area with an oil-free cleaner to remove all oil, grease, and foreign matter. Wipe until completely dry. 2. Carefully remove only the paper backing from adhesive. DO NOT touch adhesive surface with hands or remove front mask from label or plate face. 3. Exposed adhesive face must be free from all foreign matter before positioning label or plate on surface.

1. 2. 3. 4. 5.

MULTIFUNCTION CONTROL LABEL NAMEPLATE NAMEPLATE COVER RIVET HYDRAULIC FUNCTION DECAL Figure 11. Operator Compartment Label Placement

4. Press label or plate down firmly making sure that all corners are stuck down tight. Make sure that

Safety Labels Replacement

100 SRM 1185

Figure 12. Label Placement

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