Hyster D470 (N40ZR) Forklift Service Repair Manual

WARNING

General

fromtheperspectiveofanoperatorintheoperator compartmentfacingtheforks.SeeFigure1.

DONOTmakerepairsoradjustmentsunless youhavebeenproperlytrainedandspecificallyauthorizedtodoso.Repairsandadjustmentsthatareincorrectcancreatedangerous operatingconditions.

DONOToperatealifttruckthatneedsrepairs. Reporttheneedforrepairstoyoursupervisor immediately.Ifrepairisnecessary,disconnect thebatteryandattachaDONOTOPERATEtag tothecontrolhandle.

Thissectioncontainsdescriptionsoftheframecomponents,repairprocedures,andassemblyinformation.Thesecomponentsincludetheframeweldment, door,floorplate,andcovers.Theoverheadguardand basearmsarealsocoveredinthissection.

Throughoutthissection,forwardwillrefertotravel inthedirectionoftheforks,andleftandrightwillbe

Description

Theframeisavailableintwosizes:smallchassis andlargechassis.Thesmallchassisisusedforthe N30ZDR,N35-40ZR,N30ZDRS,andN35-40ZRS unitandusesasmallerdriveunit.Thesmallchassisframeisavailablewitha368.3mm(14.5in.)or 419.1mm(16.5in.)batterycompartmentwidth. ThelargechassisisusedfortheN35ZDRandN45ZR unitandusesalargerdriveunit.Thelargechassisframeisavailablewitha419.1mm(16.5in.), 469.9mm(18.5in.),or546.1mm(21.5in.)battery compartmentwidth.

Theframehasmountsforthefollowingparts:

• MastAssembly

• SteeringSystemParts

• ElectricalSystemParts

• HydraulicSystemParts

• Door,FloorPlate,AccessPanels,andCovers

Theoverheadguardfastenstothemast.Arearoperatorguardlegprovidesprotectionfortheoperator andunobstructedoperationofthelifttruck.Theoperatorguardlegfastensbetweentheoverheadguard andtheframe.Repairproceduresformajorcomponentsthatfastentotheframeareinseparatesections.Seeeachsectionforthesystemthathasthe parttoberepaired.

Repairs-General

Repairisseldomrequiredontheframeunlessthe truckhasbeenstructurallydamaged.Mosttruckrepairsinvolveremovingthesystempartsthatattach totheframe.Refertotheappropriatesectionforthe systemthatneedsrepair.Toseparatethemastfrom theframe,refertothesections Mast, Repair 4000 SRM1195and ReachCarriages 4500SRM1196.

Toreplacetheloadwheelsinthebasearms,seethe section PeriodicMaintenance 8000SRM1197or LoadWheelsinthissection.

Thecasterwheelassemblyispartofthesteering assembly.Seethesection SteeringSystem 1600 SRM1187toreplacethecasterwheelassemblyor thecasterwheels.

Toreplacethedrivewheelsortires,seethesection PeriodicMaintenance 8000SRM1197.

A. LEFT

B. RIGHT

C. FORWARD

Figure1.TravelOrientation

WELDING WARNING

Removethebatteryanddisconnectthebattery connectorbeforewelding.Weldingcancausea fireand/oranexplosion.Makesurethereisno oilorgreaseneartheweldareaandthatthe areaiswell-ventilated.

Forklifttruckframesandcomponentsmay havepolyurethanepaint.Welding,burning,or otherheatsufficienttocausethermaldecompositionofthepaintmayreleaseisocyanates. Thesechemicalsareallergicsensitizerstothe skinandrespiratorytractirritants.Overexposuremayoccurwithoutodorwarning.When performingwork,utilizegoodindustrialhygienepractices,includingremovalofallpaint (primeandfinishcoats)tothemetalaround

theareatobewelded.Uselocalventilation, and/orsupplied,air-respiratoryprotection.

CAUTION

Certainweldingrepairsrequirefactoryapproval.Structuralmemberssuchasbase arms,axleweldments,andmastcomponents requirewrittenHysterengineeringapproval beforerepairingorreplacing.Contactyour localdealerforfactoryassistance.

CAUTION

Connecttheweldinggroundclampascloseto theweldareaaspossibletopreventwelding currentfromstraying.

Onlyproperlytrained,authorizedtechniciansshould performweldingrepairs.

Covers,Panels,andPlates

FRONTFRAMEPANEL(LEFTANDRIGHT)

Removethescrewsfromtheupperandlowerendsof thefrontframepanel.Pullthelowerendofthepanel awayfromtheframeofthelifttruckandgentlywork upthesideofthepaneltopullitfromtheretainer clipssecuringthepaneltotheframe.Pullthetopend tabsoutoftheoperatorcompartmentcover.Repeat foroppositesideasnecessary.SeeFigure2.

NOTE: Onright-side,frontframepanels,ensurethe diagnosticconnectorcapis positionedcorrectlytoallowthecovertoseatproperly.

Toinstallthepanel,positiontheupperendofthe panelpartiallyintotheretainingclipontheframe. Insertthetabsontheupperendofthepanelinto theslotsintheoperatorcompartmentcover.Work thesidesofthepanelintotheretainingclipsuntilall areasofthepanelarealignedwiththeframe.Align theholesinthepanelwiththemountingbrackets ontheframeandlooselyinstallthescrewsintothe upperendandlowerendofthepanel.Makecertain thepanelisseatedcorrectlyagainsttheframeand tightenthescrewstosecureinplace.SeeFigure2.

Figure2.FrontFramePanel(LeftSide)

OPERATORCOMPARTMENTCOVER

Removethefrontframepanelsfromthelifttruck. SeeFrontFramePanel(LeftandRight).Remove thetwoscrewssecuringtheoperatorcovertothe framebrackets.Oneislocatedonthelowerright sideoftheoperatorcompartmentabovetheoperatorpresenceswitch.Theotherislocatedbesidethe overheadguardpostmount,atthebottomofthecup holder.Pulltheoperatorcompartmentcoverupfrom thefrontrightcorner.Continuepullingthecoverup alongtheedgeoftheframeinbothdirectionsuntil thecoverisfreefromtheretainingclips.SeeFigure3.

Toinstall,positionthecoverovertheelectricalcompartment.Alignthelipofthecovertotheretaining clips.Pressthelipofthecoverintotheretaining clipsstartingattheoverheadguardpostandcontinuearounduntilcompletelyseated.Aligntheholes incoverwiththemountingbracketsandinstallretainingscrewsasremoved.Installthefrontframe panelstocompleteassembly.RefertoFrontFrame Panel(LeftandRight).

DRIVEUNITCOMPARTMENTDOOR

Completelyloosenthetwosocketheadcapscrewssecuringthedriveunitcompartmentdoorclosed.The screwsarespring-loadedandareretainedtothedoor byclips.Pullthedooropenonitshinges.Toclose, pushthedoorclosedandstartbothsocketheadcapscrewslooselyintothemountingholes.Whenboth screwsarestarted,verifythatthedoorseatsproperlyagainsttheframeandtightenthescrews.

DOORPAD

Opencompartmentdoorandremovethesevencapscrewsholdingthepadtothedoor.Liftthepadover thesteeringmechanismandremove.

Toinstalthepad,loweritoverthesteeringmechanismandpositionitontothedoor.Installtheseven socketheadcapscrewsasremoved.

OPERATORBACKPAD

Side-StanceModels

Removethefivesocketheadcapscrewsretainingpad totheadjustermechanismandremovethepad.

Toinstall,positionthebackpadontotheadjuster mechanismandlooselyinstallthefivesockethead capscrewsasremoved.Verifythatthebackpadseats properlytotheadjustermechanismandtightento secureasremoved.

Forward-StanceModels

NOTE: OnmodelswithAftTravelcontrols,guide theafttravelcontrolhandlewiringharnessinto/out oftheframewheninstalling/removingtheoperator backpad.

Removetheoperatorcompartmentcovertoaccess thescrewsecuringthefrontoftheoperatorbackpad totheframe.Removethetwoscrewssecuringthe operatorbackpadtotheframeandremovethepad fromtheframe.

Figure3.OperatorCompartmentCover

Toinstall,positionthebackpadagainsttheframe asremoved.Installthetwoscrewssecuringpadto frameasremoved,andreinstalltheoperatorcompartmentcover.

OPERATORFRONTPAD

Removetheoperatorcompartmentcoverfromthelift truck.SeeOperatorCompartmentCover.Remove thescrewssecuringthepadbracketstotheframe. Pullthetopofthepadawayfromtheframeandthen liftthepadfromthelowerretainingclips.

Toinstall,positionthelowerpadbracketsintothe retainingclips.Positiontheupperendofthepadto

REMOVE

theframe.Alignthepadbracketholesandinstallthe screwstosecurethepadinplace.Installtheoperator compartmentcoverinplace.

CASTERWHEELCOVER

Removethetwosocketheadcapscrewsontopofthe casterwheelcoverandliftcoverfromtheclipssecuringittotheframe.

Toreplace,fitthebottomofthecoverintotheclips insidetheopeningandslidethecoverintoplace.Installtwosocketheadcapscrewstosecurethetopof thecoverinplace.

LoadWheels

Slightlyraisethebasearmsandsupportonblocksas describedinthe PeriodicMaintenance 8000SRM 1197.Makesurethebasearmsandloadwheelsdo notsupportanyweight.

1. Removethenut,washers,andaxlebolt.SeeFigure4.

2. Removetheloadwheelsfromthehangerbrackets.

3. Removetheaxlesleevesandbearingsfromthe loadwheels.Checkforwearorroughnessas thebearingsarerotated.Replacebothbearings ifwearorroughnessisnoted.Inspecttheload wheelsfordamageorwear.Replaceasnecessary.

CAUTION

Useahammerandasoftpunchwhenremoving bearingstoavoiddamagetobearingsand/or loadwheel.

4. Removethehangerbracketfromthebasearms andinspectthoroughly.Inspectthebasearms thoroughlyfordamage.

INSTALL WARNING

Cleaningsolventscanbeflammableandtoxic andcancauseskinirritation.Wearprotection whenhandlingsolventsandalwaysfollowthe recommendationsofthemanufacturer.

CAUTION

1. Cleanallpartswithsolventandinspectthoroughly.Replacedamagedpartsasnecessary.

2. Applylithiumgreasetothepivotcontactonthe hangerbrackets.Positionthehangerbrackets intothebasearmsandinstalltheloadwheels andaxlesleevesintothehangerbrackets.See Figure5.

CAUTION

Thebearingsarereplacedbypressingonthe outerraceofthebearingonly.Pressingortappingontheinnerracewilldamagethebearing. Useasuitabledriverwheninstallingbearings toavoiddamagetobearingsand/orloadwheel.

Replacebearingsinsetstomaintainproper wheelloadingandoperation.

NOTE: Loadwheelassembliesthathaveaxlebolts equippedwithlubefittingsuseside-shieldedbearingsandmustbegreased.Assemblieswithaxlebolts notequippedwithlubefittingsusesealedbearings andcannotbegreased.

WARNING

3. Installthebearingsintotheloadwheels.

a.SealedBearings -Installthebearingsinto theloadwheelassemblies.Positiontheaxle sleeveintotheassembly.Applyantiseizelubricanttotheaxlebolt.

b.Side-ShieldedBearings -Installonebearingintotheloadwheelwiththeshieldedside facingout.Fillthecavityinsideoftheload wheelwithgrease.Installtheotherbearing intotheloadwheelwiththeshieldedsidefacingout.Positiontheaxlesleeveintotheassembly.

4. Applygreasetothepivotcontactonthehanger brackets.Positionthehangerbracketsintothe basearmsandinstalltheloadwheelsandaxle sleevesintothehangerbrackets.

5. Installawasherontotheaxlebolt.Installthe axleboltthroughthehangerbrackets,bearings, andaxlesleevewiththethreadstotheinsideof thebasearms.

6. Installwashersandnutstotheaxlebolts.Torque to68N•m(50lbfft).

NOTE: Ifaxleshaftsareequippedwithlubefittings, greasetofillloadwheelcavity.Referto Periodic Maintenance 8000SRM1197forregularlyscheduledmaintenanceprocedures.

OverheadGuardReplacement

DONOTweldmountsforlightsoraccessories totheoverheadguard.Thestrengthofthe overheadguardcanbereducedbyweldingor heating.

Installlightsandaccessoriesortheirmounts withclamps.Thestrengthoftheoverhead guardcanbereducedifholesaredrilledinthe wronglocationoraretoolarge.Contactyour lifttruckdealerbeforeweldingordrilling holesinanypartoftheoverheadguard.

Theoverheadguardassemblyisheavy.Besure thatall liftingdevices(hoists,cables,chains, slings, etc.)aresuitableandofadequatecapacitytolifttheoverheadguard.

Theoverheadguardassemblyconsistsoftheoverheadguardandasupportpost.SeeFigure6and Figure 7.Theoverheadguardisattachedtothemast withsixcapscrews(2)andlockwashers(3).Thetop ofthesupportpostisboltedtotheoverheadguard. Thebottomofthepostfitsintoaretainerinthedrive unitcompartment.

Figure6.OverheadGuard(N35ZDR,N45ZR,N30ZDR,N35-40ZR)

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Thesizeoftheoverheadguardvariesdepending uponthebatterycompartmentsize.

REMOVE

Referto WARNING (above)beforeperformingservicetoanyoverheadguardcomponents.

1. Attachasuitableliftingdevicetotheoverhead guard.

2. Removethetwocapscrews(6)retainingthesupportposttotheoverheadguard.SeeFigure6. Pullthesupportpostoutoftheretainerinthe lifttruckframe.Removethesupportpost.

3. Removethesixcapscrews(2)andlockwashers(3) retainingtheoverheadguardtothemast.Lower theoverheadguardtothefloor.

INSTALL

Referto WARNING (above)beforeperformingservicetoanyoverheadguardcomponents.

1. Attachasuitableliftingdevicetotheoverhead guard.

2. Aligntheoverheadguardwiththetopofthemast andinstallthesixcapscrews(2)andlockwashers(3).SeeFigure6.Torquethecapscrewsto 149N•m(110lbfft).

3. Slidethesupportpostintotheretainerinthe lifttruckframe.Installthetwocapscrews(6) retainingthesupportposttotheoverheadguard.

Figure7.OverheadGuard(N30ZDRS,N35-40ZRS)

FRONTLIGHTS

Twofront(head)lightsaremountedbytheirbrackets tothefrontof theoverheadguard.

BulbReplacement

1. Removethefourscrewssecuringthelensretainerandlenstotheassembly.Holdthelens inplaceuntilallscrewshavebeenremoved thenremovethelensandretainer.Replaceas required.SeeFigure8.

2. Removethebulbfromthefixtureandreplace withnew.

CAUTION

Overtighteningthescrewscanbreakthelens.

3. Positionthelensandtheretainertothefixture andinstallthefourscrews.

AssemblyReplacement

1. Disconnectthewiringharnessfromthelightassemblyconnector.

2. Removethenutandwashersfromthecapscrew securingtheheadlightassemblytothebracket. Slidethecapscrewfromthebracketandremove theheadlight.SeeFigure9.

3. Removethebracketfrom theoverheadguardand replace,ifnecessary.

4. Installbrackettooverheadguard,ifremoved.

5. Positionthelightassemblytothebracketandinstallcapscrewandattachinghardware.Tighten slightlytoallowforadjustment.

Figure9.HeadLightMounting

RearWorkandCautionLight

Therearworkandcautionlightsareoptionsthat mounttotheoverheadguardneartherearofthe truck.Severalconfigurationsoftheseassembliesare availableandconnecttotheoptionsharness.Torepairthelightassemblies,performthefollowingprocedures.Somerepairsmaynotrequiretotaldisassembly.Performonlythestepsnecessarytosafely completetherequiredservice.SeeFigure10.

Theworklightisverysimilartothefrontlight,exceptforitsmountingplatformandlocation.Torepairorreplacetheworklight,refertotheinstructionsforrepairingorreplacingthefrontlights.See FrontLights.

CautionLight

1. Movethelifttrucktoasafe,levelareaandcompletelylowerthemast.Turnthekeyswitchto the OFF positionandattacha DONOTOPERATE tagtothecontrolhandle.Blockthedrive wheeltopreventunexpectedmovement.

2. Disconnectthebatterypowercableconnector fromthetruckconnectorlocatedontherightside oftheframe.Pullthebatterycableconnector handletoseparatethebatteryconnectorfrom thetruckconnector.

3. Removethenutssecuringthecagetothelight assembly.Removethecage.

4. Removethescrewsandwasherssecuringthe lensglobetothelightassembly.Removethelens globe.

5. Removethebulbfromthefixtureandreplaceif necessary.

6. Connectthebatteryandturnthekeyswitchto the ON position.Testforproperoperation.

7. Positionthelensglobetothelightassembly.Installscrewstosecure.

8. Positionthecageontothestudsofthelightassembly.Installnutsandwashersontostuds.

9. Removeblocksfromthewheelandreturntoservice.

Figure10.RearandCautionLight

WARNING

PaintingInstructions

Someframesandcomponentsarepaintedwith polyurethane paint.Welding,burning,orother heatsufficienttocausethermaldecomposition ofthepaintmayreleaseisocyanates.These chemicalsareallergicsensitizerstotheskin andrespiratorytractirritants.Overexposure mayoccurwithoutodorwarning.Whenheat mustbeapplied,usegoodindustrialhygiene practices, includingremovalofallpaint(prime andfinishcoats)tothemetalaroundthearea tobeheated.Uselocalventilation,and/orsupplied,air-respiratoryprotection.

Cleaningsolventsmaybeflammableand/or toxicandm aycauseskinirritation.Always wearpropereyeandskinprotection.

Alwaysuse solventsandpaintsinanareawith adequateventilation.DONOTusesolventsor paintsnearheat,fire,orelectricalequipment thatcanmakesparks.Followthepaintmanufacturer ’sinstructionsandprecautions.

CAUTION

DONOTputtapeoncylinderrodstoprotect frompaint.Useathicklayerofmultipurpose greasetoprotectcylinderrods.Cylinderscan bedamagedifoperatedwithtapeonthecylinderrod.

1. Cleanthesurfacetobepainted.Useasolvent onsurfacestobepaintedtoremovegreaseand oilbeforesanding. DONOT usesolventtoclean newpaint.Makesurealloilandgreaseisremoved.

2. Usesandpapertoremovethetopsurfaceof paintandrustfromthemetal.Allmetalsurfaceswherethepainthasbeenremovedtothe baremetalmustbeprimed.ApplyprimerBEFOREapplyingthepaint.

3. Protectallsurfacesthatwillnotbepainted. DO NOT paint:

AllPlasticCovers

SteeringHandle

DashDisplay

ControlHandles

LabelsandInformationPlates

OperatorPads

TiresandLoadWheels

ChainsandHoses

BatteryConnectors

AllSwitches

CylinderRods

PumpsandMotors

WiringHarnessesorConnectors

CAUTION

Protectelectricalcomponents,wiring,and electricalcontactsfromoverspray.

4. PaintthesurfacesusingHysterapprovedpaints. Followtheproperpaintschemeforyourlifttruck model(refertothe PartsManual forspecificinformationonpaintforyourlifttruck).

5. Installnewsafetylabels.SeeSafetyLabelsReplacement.

WARNING

SafetyLabelsReplacement

Safetylabelsareinstalledonthelifttruckto giveinformationaboutoperationandpossible hazards.Itisimportantthatallsafetylabels areinstalledonthelifttruckandcanberead.

DONOTaddtoormodifythelifttruck.Any changetothelifttruck,thetires,oritsequipmentcanchangetheliftingcapacity.Thelift truckmustberatedasequippedandthenameplatemustshowthenewcapacityrating.Contactyourlifttruckdealerforareplacement nameplate.

Cleaningsolventscanbeflammableandtoxic andcancauseskinirritation.Whenusing cleaningsolvents,alwaysfollowtherecommendationsofthemanufacturer.

Ifanadhesiveplateorlabelmustbereplaced,use thefollowingproceduretoinstallanewlabelorplate. SeeFigure11andFigure12.

1. Cleanareawithanoil-freecleanertoremoveall oil,grease,andforeignmatter.Wipeuntilcompletelydry.

2. Carefullyremoveonlythepaperbackingfrom adhesive. DONOT touchadhesivesurfacewith handsorremovefrontmaskfromlabelorplate face.

3. Exposedadhesivefacemustbefreefromallforeignmatterbeforepositioninglabelorplateon surface.

4. Presslabelorplatedownfirmlymakingsurethat allcornersarestuckdowntight.Makesurethat

allairisremovedfromunderthelabelorplate andthecornersandedgesaretight. DONOT attempttomovethelabelorplateonceithas beenstuckdown.

Figure12.LabelPlacement