Hyster N35ZDR User manual

Hyster C264 (N45ZR, N35ZDR) Forklift

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

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
•The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Hyster®
dealer. Service Manuals provide general guidelines for maintenance and service and are intended for
use by trained and experienced technicians. Failure to properly maintain equipment or to follow in-
structions contained in the Service Manual could result in damage to the products, personal injury,
property damage or death.
•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 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 making repairs. Replacement parts must meet or ex-
ceed 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 flamma-
ble. 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 hazardous situation which, if not avoided, could result in death
or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.

©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
i

TABLE OF CONTENTS (Continued)
Sideshift Cylinder ..................................................................................................................................................39
Repair ................................................................................................................................................................ 39
Front Selector Valve ..............................................................................................................................................40
Rear Selector Valve ...............................................................................................................................................41
Reach Assembly Adjustments .............................................................................................................................. 42
Check Adjustment .............................................................................................................................................42
Adjust Side Rollers 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 is for the following models:
(N35ZDR, N45ZR) [C264];
(N35ZDR2, N45ZR2) [D264];
(N30ZDR, N35-40ZR) [D470];
(N35-40ZR2, N30ZDR2) [E470];
(N30ZDRS, N35-40ZRS) [A265];
(N35-40ZRS2, N30ZDRS2) [B265]
Table of Contents
ii

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General
This section contains the descriptions and repair
procedures for single-reach and double-reach
carriages. Additional information can be found in
the following sections:
For additional information on mast
configurations, see Mast 4000SRM1195.
For additional information on hydraulic
systems for models N35ZDR, N45ZR,
N30ZDR, and N35-40ZDR, see the section
Hydraulic System 1900SRM1189. For
additional information on hydraulic systems
for models N30ZDRS and N35-40ZRS, see
the section Hydraulic System
1900SRM1307.
For the recommended service intervals and
regularly scheduled maintenance procedures,
see the section Periodic Maintenance
8000SRM1197.
Safety Procedures When Working Near Mast
WARNING
All chains, ropes, and lifting equipment MUST be
fully examined by qualified personnel at least
once a year or more at frequent intervals accord-
ing to the local conditions of use.
WARNING
Mast parts are heavy and can shift. Distances be-
tween parts are small. Serious injury can result if
part of the body is hit by parts of the mast or the
carriage.
•Never put any part of the body into or under
the mast or carriage unless all parts are
completely lowered or a safety chain is in-
stalled. Also make sure the power is off and
the key is removed. Attach a DO NOT OP-
ERATE tag to the control handle.
•DO NOT make repairs or adjustments un-
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
work on the mast.
•Be careful of the forks. When the mast is
raised, the forks can be at a height to cause
an injury.
•Move the truck to a safe location with room
to raise the mast if necessary. Block the
wheels of the truck to prevent movement.
The forks may be difficult to see when the mast is
raised. Be careful not to hit your head when work-
ing around raised forks. Also, be careful not to trip
over forks on or near the floor. If possible, remove
forks from carriage before safety chaining mast.
WHEN WORKING NEAR THE MAST, AL-
WAYS:
•Lower the mast and carriage completely.
Make sure there is no movement in the mast.
Make sure all parts of the mast, that can
move, are fully lowered.
OR
•If the mast must be in a raised position for
repairs, install a safety chain around the top
or middle crossmember of the outer weld-
ment and the crossmember of the inner weld-
ment to secure the mast.
WARNING
Perform the following step from the side of the
mast using a ladder. Never stand under the car-
riage until safety chains are installed.
1. Remove forks from carriage if possible.
2. Raise mast to align bottom crossmember(s) of
weldment(s) that move within the outer weld-
ment with a crossmember on outer weldment.
On the two-stage mast, the moving part is the
inner weldment. On the three-stage mast, it is
the intermediate weldment.
4500 SRM 1196 General
1

3. Wrap a safety chain, 9.5 mm (3/8 in.) minimum
size, around crossmembers of inner and outer
weldment. Secure it in place. See Figure 1.
4. Lower mast until safety chain stops mast.
Make sure there is no movement of mast.
5. Turn key switch to OFF, disconnect battery,
and place a DO NOT OPERATE tag on control
handle head.
6. Wrap a second safety chain, 9.5 mm (3/8 in.)
minimum size, around crossmembers of inner
and outer weldment. Secure it in place as an
additional precaution.
NOTE: The mast operator guard MUST be re-
moved to install safety chain. Remove safety chain
and install guard AFTER repairs are complete. 1. OUTER MAST WELDMENT
2. INNER MAST LOWER CROSSMEMBER
3. SAFETY CHAIN
4. CARRIAGE
Figure 1. Safety Chain the Mast
Description
The reach carriages are used to extend the forks of
the carriage. There are two types of reach car-
riages. There is a single-reach carriage with one set
of scissor arms. The other carriage 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 rear and front frame
assemblies are connected by a scissor linkage. The
top of the scissor arm weldment is fastened to the
top of the rear frame by pins located within the
rear frame assembly. The top of each scissor arm at
the front frame is fastened by pins located at the
top of the front frame assembly. On double reach
units, the ends of each set of scissor arms and scis-
sor arm weldments are fastened together by studs
with bushings. The bushings permit the arms to
pivot. Large bearings at the center pivot of each
scissor arm assembly also permit the linkage to
pivot. Refer to Figure 11 and Figure 15.
NOTE: The reach assembly can be removed from
the mast assembly with the load backrest and forks
attached. The three-stage mast assemblies can also
be removed with the reach assembly installed. Per-
form only those procedures necessary for repair.
Safety Procedures When Working Near Mast 4500 SRM 1196
2

A. SINGLE-REACH CARRIAGE B. DOUBLE-REACH CARRIAGE
1. FORK CARRIAGE
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 Carriage Assembly (Major Components)
4500 SRM 1196 Description
3

Repair - General
NOTE: Most repairs of the reach carriage can be
done without removing the carriage from the mast.
These repair procedures require that the carriage is
installed in the mast and the scissor arms are fully
extended.
WARNING
The reach carriage can fall or tip easily and cause
an injury when not installed in the mast. If the
reach carriage cannot be installed in a mast dur-
ing repair, make sure the rear frame is fastened to
a support that cannot move. The rear frame must
be in the same position as it is in the mast. The
rear frame must also be fastened so that it cannot
move on the support. The support must be strong
enough to allow full extension of the reach car-
riage without tipping.
WARNING
Hydraulic oil is hot after system operation and
can cause burns. DO NOT disconnect any hy-
draulic lines of the system until the oil for the sys-
tem is cool.
CAUTION
Make sure the lift truck is in a location that is level
and has access to a crane or other lifting device
before doing any repairs on the reach carriage.
NOTE: It is usually not necessary 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 section, as well as allWARN-
INGS and CAUTIONS.
Load Backrest
REMOVE
WARNING
The load backrest is heavy and can cause an in-
jury. Remove using a lifting device.
1. Use a hoist to secure the load backrest in posi-
tion.
2. Remove the four capscrews and lockwashers
that fasten the load backrest to the carriage
frame.
3. Lift the load backrest off the carriage frame.
INSTALL
WARNING
The load backrest is heavy and can cause an in-
jury. Install using a lifting device.
1. Raise the load backrest into position using the
lifting device.
2. Align the holes in load backrest with the
mounting holes in the carriage frame, and in-
stall the four capscrews and lockwashers.
3. Torque the capscrews to 102 N•m (75 lbf ft).
Forks
REPLACEMENT
WARNING
Forks are heavy and can cause an injury. DO NOT
try to remove forks without using a lifting device.
The forks are connected to the fork carriage by
hooks. Spring-loaded latch pins, installed in the top
fork hooks, extend into slots on the top crossmem-
ber of the carriage to hold the forks in position. See
Figure 3.
Repair - General 4500 SRM 1196
4

Remove
1. Pull the latch pin and turn it 180 degrees to
lock the pin in a retracted position.
2. Slide the fork to the fork removal notch located
in the center of the bottom crossmember of the
fork carriage.
3. Place a wooden block under the tip of the fork
and tilt the carriage forward. The bottom hook
of the fork will move through the fork removal
notch.
4. Using a lifting device and a sling, raise the fork
so the top hook of the fork is disengaged from
the top crossmember. Remove the fork from the
carriage.
Install
1. Make sure the latch pin is locked in a retracted
position.
2. Using a lifting device, move the fork or carriage
so the top hook on the fork engages the top
crossmember of the fork carriage.
3. Raise the carriage or lower the fork to move the
lower 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 a notch.
5. Release the latch pin and check that it properly
engages in a top bar notch.
Reach Carriage Assembly
REMOVE
NOTE: The following steps outline the procedures
for removing the reach carriage assembly from a
mast, which is installed to a lift truck.
1. Remove the forks. See Forks.
2. Remove the load backrest. See Load Backrest.
3. Remove the hardware securing the operator
guard from the rear of the mast, and remove
the operator guard.
WARNING
Reach carriage assemblies are heavy. Be sure
that all lifting devices are suitable and of adequate
capacity to lift the components.
4. Attach an overhead lifting device to the top of
the reach carriage assembly:
a. Install heavy-duty, industrial C-clamps to
each side of the rear frame. See Figure 4.
4500 SRM 1196 Forks
5

Figure 4. Install C-Clamps to Rear Frame
b. Ensure clamps are secure before lifting the
reach carriage assembly.
c. Install a chain loop or sling through each
clamp separately, and attach each loop to the
overhead lifting device.
5. Raise the reach carriage assembly high enough
to access the hydraulic connections and wiring
harness mounting 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 the cotter pin and chain anchor pin
securing the chain to the anchors.
NOTE: Make sure lift chains, wiring, and hoses are
secured out of the way so they do not interfere with
reach assembly removal procedures.
b. Secure chains to the mast using stiff wire to
keep them from falling from the sheaves.
Reach Carriage Assembly 4500 SRM 1196
6

c. If the mast must be disassembled or the
chains need to be cleaned/lubricated, remove
the lift chains and inspect and clean.
8. Tag and disconnect the attachment hoses from
the two fittings at bottom of the rear frame of
the reach carriage assembly. Cap or plug all
open hydraulic hoses.
9. Remove the plate securing the reach wiring
harness to the top of the rear frame. Disconnect
the wiring connector.
10. Remove the safety chains and completely lower
the reach carriage assembly to the floor.
WARNING
Mast assemblies are heavy. Be sure that all lifting
devices are suitable and of adequate capacity to
lift the components.
NOTE: Use a second lift truck or overhead lifting
device to move the reach carriage assembly.
11. Attach an overhead lifting device to the top of
the inner mast. Raise the inner mast until
clearly higher than the reach carriage assem-
bly. Move the reach carriage assembly away
from the lift truck and completely lower the
mast.
12. Disconnect the lifting device from the reach car-
riage assembly.
INSPECT
1. Inspect the rollers for excessive wear or dam-
age. Rollers with visible flat spots or cracks
should be replaced.
2. Inspect the load roller bearings and thrust
roller bearing by turning the rollers on their
shafts. Rollers with roughness or noticeable re-
strictions to turning must be replaced.
WARNING
Welding repairs to the reach carriage assembly or
mast must be factory approved by Hyster®before
the repair is performed. Written instructions out-
lining specifications 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 carriage fork bars. If
any welds are cracked, repair or replace the
damaged components as necessary.
4. Inspect the roller stub shafts. If they are dam-
aged or if there are cracks at the base of the
stub shafts, repair or replace the damaged com-
ponents as necessary.
5. Inspect the chain anchor mounts for wear or
damage.
6. Inspect the lift chains for wear or damage. If re-
moved, clean and lubricate. See Lift Chains.
NOTE: The side rollers must be adjusted while the
reach carriage assembly is removed from the mast.
7. 6.9 Mast Only (N30ZDRS and N35-40ZRS) -
Adjust the side rollers. See Adjust Side Rollers
and Load Rollers.
INSTALL
NOTE: Use a second lift truck or overhead lifting
device to move the reach carriage assembly.
1. Position the reach carriage assembly in an up-
right position in front of the mast. Align the
load rollers on the rear frame of the reach car-
riage assembly with the inner mast.
WARNING
Mast assemblies are heavy. Be sure that all lifting
devices are suitable and of adequate capacity to
lift the components.
NOTE: Use an overhead lifting device of suitable
capacity to raise the inner mast when installing the
reach carriage assembly. Use second lift truck to
position the reach carriage assembly if the first
truck is not mobile.
2. Raise the inner mast until clearly higher than
the reach carriage assembly. Position the reach
carriage assembly so the load rollers on the
rear frame are centered within the channels of
the inner mast.
4500 SRM 1196 Reach Carriage Assembly
7

3. Lower the inner mast channels onto the load
rollers of the rear frame. If the inner mast does
not lower smoothly and completely, raise the
inner mast, reposition the reach carriage as-
sembly, and lower the inner mast again.
WARNING
Reach carriage assemblies are heavy. Be sure
that all lifting devices are suitable and of adequate
capacity to lift the components.
4. Attach an overhead lifting device to the top of
the reach carriage assembly:
a. Install heavy-duty, industrial C-clamps to
each side of the rear frame. See Figure 4.
b. Install a chain loop or sling through each
clamp separately, and attach each loop to the
overhead lifting device.
5. Raise the reach carriage assembly high enough
to access the hydraulic connections and wiring
harness mounting plate on the rear frame.
6. Safety chain the reach carriage assembly in
place. See Safety Procedures When Working
Near Mast.
CAUTION
If 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 cotter pins.
8. Connect the wiring connector and install the
mounting plate to the top of the rear frame.
9. Remove caps/plugs from the attachment hoses
and fittings. Reconnect the hoses as removed.
10. Remove the safety chains and completely lower
the reach carriage assembly.
11. Remove the C-clamps and lifting device from
the reach carriage assembly.
12. Raise and lower the mast several times to re-
move air from the system. Cycle the sideshift
function and the tilt function several times to
remove air from the circuit. Check for proper
operation.
13. Check the hydraulic oil level and add as re-
quired.
14. Check reach carriage assembly height and
alignment and adjust the lift chains as re-
quired. See Reach Assembly Adjustments.
15. Install the load backrest. See Load Backrest.
16. Install the forks. See Forks.
17. Install the operator guard as removed.
Reach Carriage Assembly 4500 SRM 1196
8

Reach Carriage Assembly Repair
NOTE: Most repairs of the reach carriage assembly
can be done without removing the reach carriage
assembly from the mast. These repair procedures
require that the reach carriage assembly is instal-
led in the mast and the scissor arms are fully ex-
tended.
WARNING
The reach carriage assembly can fall or tip easily
and cause an injury when not installed in the
mast. If the reach carriage assembly cannot be in-
stalled in a mast during repair, make sure the rear
frame is fastened to a support that cannot move.
The rear frame must be 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 assembly without tip-
ping.
WARNING
Hydraulic oil is hot after system operation and
can cause burns. DO NOT disconnect any hy-
draulic lines of the system until the oil for the sys-
tem is cool.
CAUTION
Make sure the lift truck is in a location that is level
and has access to a crane or other lifting device
before doing any repairs on the reach carriage as-
sembly.
It is usually not necessary to completely disassem-
ble the reach carriage assembly. Do only the steps
of the procedures necessary to make the required
repairs.
4500 SRM 1196 Reach Carriage Assembly Repair
9

Load Rollers Repair
1. Remove the rear frame from the mast as re-
quired to remove and install the load rollers.
See Reach Carriage Assembly.
WARNING
Be careful when removing or installing snap
rings. Snap rings can eject during removal or in-
stallation with enough force to cause an injury. Al-
ways use the proper snap ring pliers and wear eye
and face protection during removal or installation.
2. Remove the snap rings from the load rollers.
See Figure 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 shaft. Re-
place as necessary.
1. LOAD ROLLER (WITH SNAP RING REMOVED)
2. PRY BAR
3. REAR FRAME
Figure 6. Removing Load Roller (6.9 Mast)
(N30ZDRS and N35-40ZRS)
NOTE: Tag and identify the shim packs for each
roller.
4. Remove the shims from the stub shaft.
5. Use a cloth to clean each load roller. Inspect the
load rollers for cracks, flat spots, or bearings
that do not turn freely. Replace any roller that
shows wear or is damaged.
Load Rollers Repair 4500 SRM 1196
10

Side Rollers Repair (6.9 Mast Only) (N30ZDRS and N35-40ZRS)
1. Remove the reach carriage assembly from the
mast to adjust or replace the side rollers. See
Reach Carriage Assembly.
NOTE: Make note of the position of the shims.
Shim requirements should be similar to the previ-
ous requirements.
2. Remove the capscrews, shim packs, and wash-
ers that secure the side roller bracket.
3. Inspect and replace all damaged or worn parts.
CAUTION
Correct placement of shims is critical for the oper-
ation of the reach carriage assembly. Unless the
shims are installed correctly, the reach carriage
assembly will not operate properly.
4. Install the side rollers using shim 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
NOTE: It is not necessary to remove the reach car-
riage assembly from the mast to service the front
frame.
The front frame is located at the front of the reach
carriage assembly and is attached to the outer end
of the scissor arms. The assembly consists of a tilt-
ing frame, a fixed frame with tilt cylinder, and
front selector valve hydraulics. See Figure 7. When
equipped with optional sideshift, a movable fork
carriage and the sideshift cylinder are included.
1. FIXED FRAME
2. SELECTOR VALVE
3. FORK CARRIAGE
4. SIDE SHIFT CYLINDER
5. TILT CYLINDER
Figure 7. Front Frame Assembly
4500 SRM 1196 Side Rollers Repair (6.9 Mast Only) (N30ZDRS and N35-40ZRS)
11

WARNING
There are pinch points on the reach carriage as-
sembly that can cause an injury. Use clamps and
blocks to prevent the scissor arms from moving.
Install the clamps and blocks at the channels of
the rear frame to make sure the load bearings
cannot move in the channel. See Figure 8.
NOTE: Use safety chains on the rear frame and
mast weldments to keep the reach carriage assem-
bly and mast weldments from moving. Install the
safety chains as described in Safety Procedures
When Working Near Mast in this section.
NOTE: Make sure the reach carriage assembly is
in the fully-extended position. The front frame
should be removed with the forks removed.
1. Remove the forks and the load backrest. Refer
to Load Backrest and Forks.
2. Extend the reach fully and install blocks and
clamps inside the channels of the rear frame to
make sure the load rollers cannot move in the
channel. See Figure 8.
3. Tag and disconnect the hydraulic lines from the
hose guide at the valve. Cap or plug the hy-
draulic lines and valve ports to prevent dirt
from entering the system. Make note of the lo-
cation of all cable 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. Connect an overhead lifting device (crane) to
the top of the front frame.
6. Remove the screws that retain the pivot pins in
the front frame to the inner scissor arms. Re-
move the pivot pins.
7. Use the crane to lift the front frame high
enough to allow the inner scissor arm rollers to
come out of the bottom of the front frame chan-
nels. Move the front frame away from the lift
truck and place it face down on the floor.
DISASSEMBLE (WITH SIDESHIFT)
For the following procedures, refer to Figure 9.
1. Orient front frame assembly with roller guides
down and secure the unit.
2. Remove the selector valve. Refer to Front Selec-
tor Valve.
1. REAR FRAME ASSEMBLY
2. LOAD BEARING
3. WOOD BLOCK
4. CLAMP
Figure 8. Blocking the Rear Frame
3. Remove tilt cylinder nuts (20).
4. Remove brackets and capscrews (24) from the
fork carriage.
5. Remove fork carriage.
6. Remove wear strips (2, 3, and 19).
7. Remove capscrews (6), washers (5), and re-
tainer plates (4) from each side of tilting frame.
8. Use a punch to remove pins (8) from each side
of tilting frame.
9. Remove tilting frame from fixed frame.
Reach Assembly Front Frame 4500 SRM 1196
12

10. Remove bushings from fixed frame.
11. Disassemble sideshift cylinder only if needed
for service. See Sideshift Cylinder.
12. Remove trunnion caps, capscrews (12), and pins
(25) from each side of tilt cylinder.
13. Remove tilt cylinder.
14. Remove bushings from tilt cylinder.
15. Disassemble tilt cylinder 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. CAPSCREW
13. ROD
14. WIPER
15. SEAL
16. SLEEVE
17. SEAL
18. TILTING FRAME
19. WEAR STRIP
20. NUT
21. FORK CARRIAGE
22. CAPSCREW
23. BRACKET
24. CAPSCREW
25. PIN
26. BUSHING
27. LUBE FITTING
28. PIVOT PIN
29. RETAINER CAPSCREW
Figure 9. Front Frame With Sideshifter
4500 SRM 1196 Reach Assembly Front Frame
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DISASSEMBLE (WITHOUT SIDESHIFT)
For the following procedures, refer to Figure 10.
1. Orient front frame assembly with roller guides
down and secure the unit.
2. Remove the selector valve. Refer to Front Selec-
tor Valve.
3. Remove nuts from tilt cylinder. See Figure 10.
4. Remove capscrews (3), washers (2), and re-
tainer plate (1) from each side of tilting frame.
5. Use a punch to remove 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 cylinder. Remove bushings from tilt
cylinder.
10. Disassemble tilt cylinder if repair is necessary.
See Tilt Cylinder.
1. RETENTION PLATE
2. LOCKWASHER
3. CAPSCREW
4. PIN
5. CAPSCREW
6. TRUNNION CAP
7. FIXED FRAME
8. PIVOT PIN
9. BUSHING
10. BUSHING
11. TILT CYLINDER
12. TILTING FRAME
13. CAPSCREW
14. NUT
Figure 10. Front Frame Without Sideshifter
Reach Assembly Front Frame 4500 SRM 1196
14