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 prod-
uct. 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 expe-
rienced technicians. Failure to properly maintain equipment or to follow instructions 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 exceed the
specifications of the original equipment manufacturer.

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

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

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

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

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

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

WARNING
Indicates a 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.
Reach Carriages Table of Contents

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 ................................................................................................................................................................... 5
Replacement................................................................................................................................................... 5
Remove....................................................................................................................................................... 5
Install ......................................................................................................................................................... 5
Reach Carriage Assembly.................................................................................................................................. 5
Remove ........................................................................................................................................................... 5
Inspect ............................................................................................................................................................ 7
Install ............................................................................................................................................................. 7
Reach Carriage Assembly Repair ..................................................................................................................... 8
Load Rollers Repair ........................................................................................................................................... 9
Side Rollers Repair (6.9 Mast Only) (N30ZDRS and N35-40ZRS).................................................................. 9
Reach Assembly Front Frame ........................................................................................................................... 10
Remove ........................................................................................................................................................... 10
Disassemble (With Sideshift) ........................................................................................................................ 11
Disassemble (Without Sideshift) .................................................................................................................. 13
Clean and Inspect .......................................................................................................................................... 14
Assemble (With Sideshift) ............................................................................................................................. 14
Assemble (Without Sideshift) ....................................................................................................................... 14
Install ............................................................................................................................................................. 14
Single-Reach Scissor Arms ................................................................................................................................ 15
Remove and Disassemble .............................................................................................................................. 15
Clean and Inspect .......................................................................................................................................... 18
Assemble and Install ..................................................................................................................................... 18
Double-Reach Scissor Arms............................................................................................................................... 20
Disassemble ................................................................................................................................................... 20
Clean and Inspect .......................................................................................................................................... 24
Assemble ........................................................................................................................................................ 24
Rear Frame Assembly........................................................................................................................................ 26
Remove ........................................................................................................................................................... 26
Disassemble ................................................................................................................................................... 28
Clean and Inspect .......................................................................................................................................... 29
Assemble ........................................................................................................................................................ 29
Install ............................................................................................................................................................. 29
Reach Cylinders ................................................................................................................................................. 30
Remove ........................................................................................................................................................... 30
Disassemble ................................................................................................................................................... 33
Clean and Inspect .......................................................................................................................................... 33
Assemble ........................................................................................................................................................ 34
Install ............................................................................................................................................................. 34
Tilt Cylinder ....................................................................................................................................................... 34
Remove ........................................................................................................................................................... 34
Clean, Inspect, and Repair............................................................................................................................ 35
Install ............................................................................................................................................................. 36
Sideshift Cylinder .............................................................................................................................................. 36

©2013 HYSTER COMPANY i

Table of Contents Reach Carriages

TABLE OF CONTENTS (Continued)

Repair ............................................................................................................................................................. 36
Front Selector Valve........................................................................................................................................... 36
Rear Selector Valve ............................................................................................................................................ 38
Reach Assembly Adjustments ........................................................................................................................... 39
Check Adjustment ......................................................................................................................................... 39
Adjust Side Rollers and Load Rollers ........................................................................................................... 40
Adjust Reach Cylinders ................................................................................................................................. 41
Lift Chains.......................................................................................................................................................... 42
Inspect ............................................................................................................................................................ 42
Clean and Lubricate ...................................................................................................................................... 43
Adjust Main-Lift Chains ............................................................................................................................... 43
Adjust Free-Lift Chains................................................................................................................................. 43
Specifications...................................................................................................................................................... 45
Troubleshooting ................................................................................................................................................ 48

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]

ii
4500 SRM 1196 Safety Procedures When Working Near Mast

General
This section contains the descriptions and repair pro- N35-40ZDR, see the section Hydraulic System
cedures for single-reach and double-reach carriages. 1900 SRM 1189. For additional information
Additional information can be found in the following on hydraulic systems for models N30ZDRS and
sections: N35-40ZRS, see the section Hydraulic System
For additional information on mast configura- 1900 SRM 1307.
tions, see Mast, Repair 4000 SRM 1195. For the recommended service intervals and regu-
For additional information on hydraulic sys- larly scheduled maintenance procedures, see the
tems for models N35ZDR, N45ZR, N30ZDR, and section Periodic Maintenance 8000 SRM 1197.

Safety Procedures When Working Near Mast

WHEN WORKING NEAR THE MAST, ALWAYS:
WARNING • Lower the mast and carriage completely. Make
All chains, ropes, and lifting equipment MUST sure there is no movement in the mast. Make sure
be fully examined by qualified personnel at all parts of the mast, that can move, are fully low-
least once a year or more at frequent intervals ered.
according to the local conditions of use.
OR
WARNING
• If the mast must be in a raised position for re-
Mast parts are heavy and can shift. Distances pairs, install a safety chain around the top or mid-
between parts are small. Serious injury can re- dle crossmember of the outer weldment and the
sult if part of the body is hit by parts of the mast crossmember of the inner weldment to secure the
or the carriage. mast.
• Never put any part of the body into or under
the mast or carriage unless all parts are com-
pletely lowered or a safety chain is installed. WARNING
Also make sure the power is off and the key Perform the following step from the side of the
is removed. Attach a DO NOT OPERATE tag mast using a ladder. Never stand under the car-
to the control handle. riage until safety chains are installed.
• DO NOT make repairs or adjustments unless
1. Remove forks from carriage if possible.
specifically authorized to do so. Repairs and
adjustments must be performed by trained 2. Raise mast to align bottom crossmember(s) of
service technicians. weldment(s) that move within the outer weld-
• DO NOT climb on the mast or lift truck at any ment with a crossmember on outer weldment.
time. Use a ladder or personnel lift to work On the two-stage mast, the moving part is the
on the mast. inner weldment. On the three-stage mast, it is
• Be careful of the forks. When the mast is the intermediate weldment.
raised, the forks can be at a height to cause
an injury. 3. Wrap a safety chain, 9.5 mm (3/8 in.) minimum
• Move the truck to a safe location with room to size, around crossmembers of inner and outer
raise the mast if necessary. Block the wheels weldment. Secure it in place. See Figure 1.
of the truck to prevent movement.
4. Lower mast until safety chain stops mast. Make
The forks may be difficult to see when the mast is sure there is no movement of mast.
raised. Be careful not to hit your head when working
around raised forks. Also, be careful not to trip over 5. Turn key switch to OFF, disconnect battery, and
forks on or near the floor. If possible, remove forks place a DO NOT OPERATE tag on control han-
from carriage before safety chaining mast. dle head.

1
Description 4500 SRM 1196

6. Wrap a second safety chain, 9.5 mm (3/8 in.) min-

imum size, around crossmembers of inner and
outer weldment. Secure it in place as an addi-
tional precaution.

NOTE: The mast operator guard MUST be removed

to install safety chain. Remove safety chain and in-
stall 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 assembly. On double reach units, the ends of each set
the carriage. There are two types of reach carriages. of scissor arms and scissor arm weldments are fas-
There is a single-reach carriage with one set of scis- tened together by studs with bushings. The bushings
sor arms. The other carriage has two sets of scissor permit the arms to pivot. Large bearings at the cen-
arms for double reach. See Figure 2. Both carriages ter pivot of each scissor arm assembly also permit the
have a tilt cylinder to tilt the forks. Each carriage is linkage to pivot. Refer to Figure 11 and Figure 15.
available with sideshift function. Refer to Figure 9
and Figure 10. The rear and front frame assemblies NOTE: The reach assembly can be removed from the
are connected by a scissor linkage. The top of the scis- mast assembly with the load backrest and forks at-
sor arm weldment is fastened to the top of the rear tached. The three-stage mast assemblies can also be
frame by pins located within the rear frame assem- removed with the reach assembly installed. Perform
bly. The top of each scissor arm at the front frame is only those procedures necessary for repair.
fastened by pins located at the top of the front frame

2
4500 SRM 1196 Description

A. SINGLE-REACH CARRIAGE B. DOUBLE-REACH CARRIAGE

1. FORK CARRIAGE 6. FRONT FRAME ASSEMBLY
2. TILT CYLINDER 7. FRONT SELECTOR VALVE
3. REAR FRAME ASSEMBLY 8. VALVE COVER PLATE
4. REAR SELECTOR VALVE 9. HOSE AND WIRING GUIDE
5. SCISSOR ARMS 10. REACH CYLINDER

Figure 2. Reach Carriage Assembly (Major Components)

3
Load Backrest 4500 SRM 1196

Repair - General
NOTE: Most repairs of the reach carriage can be
WARNING
done without removing the carriage from the mast.
These repair procedures require that the carriage is Hydraulic oil is hot after system operation and
installed in the mast and the scissor arms are fully can cause burns. DO NOT disconnect any hy-
extended. draulic lines of the system until the oil for the
system is cool.
WARNING
The reach carriage can fall or tip easily and CAUTION
cause an injury when not installed in the mast. Make sure the lift truck is in a location that is
If the reach carriage cannot be installed in a level and has access to a crane or other lifting
mast during repair, make sure the rear frame device before doing any repairs on the reach
is fastened to a support that cannot move. The carriage.
rear frame must be in the same position as it is
in the mast. The rear frame must also be fas- NOTE: It is usually not necessary to completely dis-
tened so that it cannot move on the support. assemble the reach carriage. Do only the steps of the
The support must be strong enough to allow procedures necessary to make the required repairs.
full extension of the reach carriage without tip- Read and follow the Safety Procedures When Work-
ping. ing Near Mast in this section, as well as all WARN-
INGS and CAUTIONS.

Load Backrest
REMOVE INSTALL

WARNING WARNING
The load backrest is heavy and can cause an The load backrest is heavy and can cause an
injury. Remove using a lifting device. injury. Install using a lifting device.

1. Use a hoist to secure the load backrest in posi- 1. Raise the load backrest into position using the
tion. lifting device.

2. Remove the four capscrews and lockwashers that 2. Align the holes in load backrest with the mount-
fasten the load backrest to the carriage frame. ing holes in the carriage frame, and install the
four capscrews and lockwashers.
3. Lift the load backrest off the carriage frame.
3. Torque the capscrews to 102 N•m (75 lbf ft).

4
4500 SRM 1196 Reach Carriage Assembly

Forks
REPLACEMENT 2. Using a lifting device, move the fork or carriage
so the top hook on the fork engages the top cross-
WARNING member of the fork carriage.
Forks are heavy and can cause an injury. DO 3. Raise the carriage or lower the fork to move the
NOT try to remove forks without using a lifting lower hook through the removal notch.
device.
4. Slide the fork on the carriage so both upper and
The forks are connected to the fork carriage by hooks. lower hooks are engaged and the latch pin aligns
Spring-loaded latch pins, installed in the top fork with a notch.
hooks, extend into slots on the top crossmember of
the carriage to hold the forks in position. See Fig- 5. Release the latch pin and check that it properly
ure 3. engages in a top bar notch.

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 1. FORK 4. SPRING
crossmember. Remove the fork from the carriage. 2. BUTTON CAP 5. PIN
3. LATCH PIN
Install
Figure 3. Forks
1. Make sure the latch pin is locked in a retracted
position.

Reach Carriage Assembly

REMOVE WARNING
NOTE: The following steps outline the procedures for Reach carriage assemblies are heavy. Be sure
removing the reach carriage assembly from a mast, that all lifting devices are suitable and of ade-
which is installed to a lift truck. quate capacity to lift the components.

1. Remove the forks. See Forks. 4. Attach an overhead lifting device to the top of the
reach carriage assembly:
2. Remove the load backrest. See Load Backrest.
a. Install heavy-duty, industrial C-clamps to
3. Remove the hardware securing the operator each side of the rear frame. See Figure 4.
guard from the rear of the mast, and remove the
operator guard.

5
Reach Carriage Assembly 4500 SRM 1196

b. Ensure clamps are secure before lifting the 7. Disconnect the lift chains from the reach carriage
reach carriage assembly. assembly:

c. Install a chain loop or sling through each a. Remove the cotter pin and chain anchor pin
clamp separately, and attach each loop to the securing the chain to the anchors.
overhead lifting device.
NOTE: Make sure lift chains, wiring, and hoses are
5. Raise the reach carriage assembly high enough secured out of the way so they do not interfere with
to access the hydraulic connections and wiring reach assembly removal procedures.
harness mounting plate on the rear frame.
b. Secure chains to the mast using stiff wire to
6. Safety chain the reach carriage assembly in keep them from falling from the sheaves.
place. See Safety Procedures When Working
Near Mast. c. If the mast must be disassembled or the
chains need to be cleaned/lubricated, remove
the lift chains and inspect and clean.

Figure 4. Install C-Clamps to Rear Frame

6
4500 SRM 1196 Reach Carriage Assembly

8. Tag and disconnect the attachment hoses from 4. Inspect the roller stub shafts. If they are dam-
the two fittings at bottom of the rear frame of aged or if there are cracks at the base of the
the reach carriage assembly. Cap or plug all open stub shafts, repair or replace the damaged com-
hydraulic hoses. ponents as necessary.

9. Remove the plate securing the reach wiring har- 5. Inspect the chain anchor mounts for wear or
ness to the top of the rear frame. Disconnect the damage.
wiring connector.
6. Inspect the lift chains for wear or damage. If
10. Remove the safety chains and completely lower removed, clean and lubricate. See Lift Chains.
the reach carriage assembly to the floor.
NOTE: The side rollers must be adjusted while the
reach carriage assembly is removed from the mast.
WARNING
Mast assemblies are heavy. Be sure that all lift- 7. 6.9 Mast Only (N30ZDRS and N35-40ZRS) -
ing devices are suitable and of adequate capac- Adjust the side rollers. See Adjust Side Rollers
ity to lift the components. and Load Rollers.

NOTE: Use a second lift truck or overhead lifting de- INSTALL

vice to move the reach carriage assembly.
NOTE: Use a second lift truck or overhead lifting de-
11. Attach an overhead lifting device to the top of the vice to move the reach carriage assembly.
inner mast. Raise the inner mast until clearly
higher than the reach carriage assembly. Move 1. Position the reach carriage assembly in an up-
the reach carriage assembly away from the lift right position in front of the mast. Align the load
truck and completely lower the mast. rollers on the rear frame of the reach carriage as-
sembly with the inner mast.
12. Disconnect the lifting device from the reach car-
riage assembly.
WARNING
INSPECT Mast assemblies are heavy. Be sure that all lift-
ing devices are suitable and of adequate capac-
1. Inspect the rollers for excessive wear or damage. ity to lift the components.
Rollers with visible flat spots or cracks should be
replaced. NOTE: Use an overhead lifting device of suitable ca-
pacity to raise the inner mast when installing the
2. Inspect the load roller bearings and thrust roller reach carriage assembly. Use second lift truck to po-
bearing by turning the rollers on their shafts. sition the reach carriage assembly if the first truck is
Rollers with roughness or noticeable restrictions not mobile.
to turning must be replaced.
2. Raise the inner mast until clearly higher than
the reach carriage assembly. Position the reach
WARNING carriage assembly so the load rollers on the rear
Welding repairs to the reach carriage assem- frame are centered within the channels of the in-
bly or mast must be factory approved by Hys- ner mast.
ter® before the repair is performed. Written
instructions outlining specifications and weld- 3. Lower the inner mast channels onto the load
ing techniques will be provided upon approval rollers of the rear frame. If the inner mast does
to ensure the structural integrity and safety of not lower smoothly and completely, raise the
the repair. inner mast, reposition the reach carriage assem-
bly, and lower the inner mast again.
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 dam-
aged components as necessary.

7
Reach Carriage Assembly Repair 4500 SRM 1196

8. Connect the wiring connector and install the

WARNING mounting plate to the top of the rear frame.
Reach carriage assemblies are heavy. Be sure
that all lifting devices are suitable and of ade- 9. Remove caps/plugs from the attachment hoses
quate capacity to lift the components. and fittings. Reconnect the hoses as removed.

4. Attach an overhead lifting device to the top of the 10. Remove the safety chains and completely lower
reach carriage assembly: the reach carriage assembly.

a. Install heavy-duty, industrial C-clamps to 11. Remove the C-clamps and lifting device from the
each side of the rear frame. See Figure 4. reach carriage assembly.

b. Install a chain loop or sling through each 12. Raise and lower the mast several times to remove
clamp separately, and attach each loop to the air from the system. Cycle the sideshift function
overhead lifting device. and the tilt function several times to remove air
from the circuit. Check for proper operation.
5. Raise the reach carriage assembly high enough
to access the hydraulic connections and wiring 13. Check the hydraulic oil level and add as required.
harness mounting plate on the rear frame.
14. Check reach carriage assembly height and align-
6. Safety chain the reach carriage assembly in ment and adjust the lift chains as required. See
place. See Safety Procedures When Working Reach Assembly Adjustments.
Near Mast.
15. Install the load backrest. See Load Backrest.

CAUTION 16. Install the forks. See Forks.

If reusing chains, make sure chains have been
properly inspected, cleaned, and lubricated. 17. Install the operator guard as removed.
See Lift Chains.

7. Reconnect the lift chains to anchors on reach car-

riage assembly as removed. Install anchor pins
and cotter pins.

Reach Carriage Assembly Repair

NOTE: Most repairs of the reach carriage assembly
WARNING
can be done without removing the reach carriage as-
sembly from the mast. These repair procedures re- Hydraulic oil is hot after system operation and
quire that the reach carriage assembly is installed in can cause burns. DO NOT disconnect any hy-
the mast and the scissor arms are fully extended. draulic lines of the system until the oil for the
system is cool.

WARNING
The reach carriage assembly can fall or tip eas-
CAUTION
ily and cause an injury when not installed in Make sure the lift truck is in a location that is
the mast. If the reach carriage assembly can- level and has access to a crane or other lifting
not be installed in a mast during repair, make device before doing any repairs on the reach
sure the rear frame is fastened to a support carriage assembly.
that cannot move. The rear frame must be in
It is usually not necessary to completely disassemble
the same position as it is in the mast. The rear
the reach carriage assembly. Do only the steps of the
frame must also be fastened so it cannot move
procedures necessary to make the required repairs.
on the support. The support must be strong
enough to allow full extension of the reach car-
riage assembly without tipping.

8
4500 SRM 1196 Side Rollers Repair (6.9 Mast Only) (N30ZDRS and N35-40ZRS)

Load Rollers Repair

1. Remove the rear frame from the mast as required 3. Remove the load roller from the stub shaft. Re-
to remove and install the load rollers. See Reach place as necessary.
Carriage Assembly.

WARNING
Be careful when removing or installing snap
rings. Snap rings can eject during removal or
installation with enough force to cause an in-
jury. Always use the proper snap ring pliers
and wear eye and face protection during re-
moval or installation.

2. Remove the snap rings from the load rollers. See

Figure 5.

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.
1. SNAP RING 3. SPACER 4. Remove the shims from the stub shaft.
2. LOAD ROLLER 4. STUB SHAFT
5. Use a cloth to clean each load roller. Inspect the
Figure 5. Load Roller Assembly load rollers for cracks, flat spots, or bearings that
NOTE: Lightly pry the load roller from the stub shaft do not turn freely. Replace any roller that shows
if necessary. See Figure 6. wear or is damaged.

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
CAUTION
Reach Carriage Assembly. Correct placement of shims is critical for the
operation of the reach carriage assembly. Un-
NOTE: Make note of the position of the shims. Shim less the shims are installed correctly, the reach
requirements should be similar to the previous re- carriage assembly will not operate properly.
quirements.
4. Install the side rollers using shim packs, wash-
2. Remove the capscrews, shim packs, and washers ers, and capscrews.
that secure the side roller bracket.
5. Measure and adjust the side rollers as necessary.
3. Inspect and replace all damaged or worn parts. See Reach Assembly Adjustments.

9
Reach Assembly Front Frame 4500 SRM 1196

6. Install the reach carriage assembly to the mast.

Reach Assembly Front Frame

REMOVE 4. Tag and disconnect the wire connectors from the
hose guide.
NOTE: It is not necessary to remove the reach car-
riage assembly from the mast to service the front 5. Connect an overhead lifting device (crane) to the
frame. top of the front frame.

The front frame is located at the front of the reach 6. Remove the screws that retain the pivot pins in
carriage assembly and is attached to the outer end the front frame to the inner scissor arms. Re-
of the scissor arms. The assembly consists of a move the pivot pins.
tilting frame, a fixed frame with tilt cylinder, and
front selector valve hydraulics. See Figure 7. When 7. Use the crane to lift the front frame high enough
equipped with optional sideshift, a movable fork to allow the inner scissor arm rollers to come out
carriage and the sideshift cylinder are included. of the bottom of the front frame channels. Move
the front frame away from the lift truck and place
it face down on the floor.
WARNING
There are pinch points on the reach carriage
assembly 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 assembly 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 1. FIXED FRAME
hose guide at the valve. Cap or plug the hy- 2. SELECTOR VALVE
draulic lines and valve ports to prevent dirt from 3. FORK CARRIAGE
entering the system. Make note of the location 4. SIDE SHIFT CYLINDER
5. TILT CYLINDER
of all cable ties for replacement during installa-
tion. Disconnect the sideshift cylinder hydraulics Figure 7. Front Frame Assembly
if equipped. See Sideshift Cylinder, Repair.

10
4500 SRM 1196 Reach Assembly Front Frame

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 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 retainer

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.

10. Remove bushings from fixed frame.

11. Disassemble sideshift cylinder only if needed for

service. See Sideshift Cylinder.
1. REAR FRAME ASSEMBLY 12. Remove trunnion caps, capscrews (12), and pins
2. LOAD BEARING (25) from each side of tilt cylinder.
3. WOOD BLOCK
4. CLAMP
13. Remove tilt cylinder.
Figure 8. Blocking the Rear Frame
14. Remove bushings from tilt cylinder.
DISASSEMBLE (WITH SIDESHIFT) 15. Disassemble tilt cylinder only if repair is neces-
sary. See Tilt Cylinder.
For the following procedures, refer to Figure 9.

11
Reach Assembly Front Frame 4500 SRM 1196

1. LUBE FITTING 16. SLEEVE

2. WEAR STRIP 17. SEAL
3. WEAR STRIP 18. TILTING FRAME
4. RETAINER PLATE 19. WEAR STRIP
5. LOCKWASHER 20. NUT
6. CAPSCREW 21. FORK CARRIAGE
7. TILT CYLINDER 22. CAPSCREW
8. PIVOT PIN 23. BRACKET
9. BUSHING 24. CAPSCREW
10. FIXED FRAME 25. PIN
11. TRUNNION CAP 26. BUSHING
12. CAPSCREW 27. LUBE FITTING
13. ROD 28. PIVOT PIN
14. WIPER 29. RETAINER CAPSCREW
15. SEAL

Figure 9. Front Frame With Sideshifter

12
4500 SRM 1196 Reach Assembly Front Frame

DISASSEMBLE (WITHOUT SIDESHIFT) 5. Use a punch to remove pivot pins (8) from each
side of tilting frame.
For the following procedures, refer to Figure 10.
6. Remove tilting frame from fixed frame.
1. Orient front frame assembly with roller guides
down and secure the unit. 7. Remove bushings from fixed frame.

2. Remove the selector valve. Refer to Front Selec- 8. Remove tilt cylinder trunnion caps, capscrews
tor Valve. (5), and pin (4).

3. Remove nuts from tilt cylinder. See Figure 10. 9. Remove tilt cylinder. Remove bushings from tilt
cylinder.
4. Remove capscrews (3), washers (2), and retainer
plate (1) from each side of tilting frame. 10. Disassemble tilt cylinder if repair is necessary.
See Tilt Cylinder.

1. RETENTION PLATE 8. PIVOT PIN

2. LOCKWASHER 9. BUSHING
3. CAPSCREW 10. BUSHING
4. PIN 11. TILT CYLINDER
5. CAPSCREW 12. TILTING FRAME
6. TRUNNION CAP 13. CAPSCREW
7. FIXED FRAME 14. NUT

Figure 10. Front Frame Without Sideshifter

13
Reach Assembly Front Frame 4500 SRM 1196

CLEAN AND INSPECT 11. Install tilt cylinder nuts (20) as removed.

12. Install the selector valve. Refer to Front Selector

WARNING Valve.
Cleaning solvents can be flammable and toxic
and can cause skin irritation. Always wear 13. Install load backrest. See Load Backrest section.
the proper protective equipment including
eye protection and petroleum resistant gloves 14. Install forks. Refer to Forks.
when handling. Always follow the recommen-
dations of the manufacturer. ASSEMBLE (WITHOUT SIDESHIFT)
For the following procedures, see Figure 10.
CAUTION
DO NOT use steam to clean the load bearings. 1. Install bushings to fixed frame if removed.
DO NOT use compressed air or immerse in sol-
2. Assemble tilt cylinder if necessary. See Tilt
vent to clean the bearings. The bearings are
Cylinder.
sealed and permanently lubricated. Wipe bear-
ings off with a clean cloth and turn to check for 3. Install tilt cylinder bushings and install tilt
proper operation. Replace if movement is re- cylinder to fixed frame.
stricted or if bearing does not turn smoothly.
4. Install tilt cylinder trunnion cap and hardware
Clean all of the parts of the front frame with solvent. (4 and 5).
Dry the parts with compressed air. Inspect the parts
of the front frame for damage and wear. Replace all 5. Position tilting frame to fixed frame. Align pivot
bushings. pin holes using a prybar.

ASSEMBLE (WITH SIDESHIFT) 6. Install pivot pins (8) through the tilting frame
into the fixed frame. Secure in place using pin-
For the following procedures, refer to Figure 9. retaining hardware (1, 2, and 3).

1. Assemble tilt cylinder if necessary. See Tilt 7. Install tilt cylinder nuts as removed.
Cylinder.
8. Install the selector valve if removed. Refer to
2. Install tilt cylinder bushings and install tilt Front Selector Valve.
cylinder to fixed frame.
9. Install load backrest. See Load Backrest section.
3. Install trunnion cap and hardware (12 and 25) to
tilt cylinder. 10. Install forks. Refer to Forks.

4. Assemble sideshift cylinder (13 through 17) if INSTALL

disassembled. Refer to Sideshift Cylinder Re-
pair. WARNING
5. Install bushings to fixed frame if removed. The points between the scissor arms and the
front frame is a pinch point and can cause an
6. Position tilting frame to fixed frame. Use a pry- injury. DO NOT put any part of your body be-
bar to align pivot pin holes. tween these assemblies. Use a screwdriver or
other tool to move the bearing blocks or assem-
7. Install pivot pins (8) through tilting frame into blies into the correct positions.
fixed frame. Secure using pin-retaining hard-
ware (4, 5, and 6). 1. Use multipurpose grease to lubricate the bush-
ings on the inner and outer scissor arms. Use
8. Install wear strips (2, 3, and 19) to tilting frame. multipurpose grease to lube the bottom bearings
in the channel at the bottom of the front frame.
9. Install fork carriage to tilting frame.

10. Install brackets and hardware (24) to fork car-

riage.

14
4500 SRM 1196 Single-Reach Scissor Arms

2. Use a crane to lift the front frame. Align the front 4. After all hydraulic lines are connected, operate
frame with the outer scissor arms. Install the the functions to check for leaks and correct oper-
pivot pins that retain the inner scissor arms to ation. Remove the air from the system and ad-
the front frame. just the stroke of the tilt cylinder as described in
Reach Assembly Adjustments.
3. Install the brackets and hardware to retain the
pivot pins. 5. Install the forks and load backrest as removed.
See Forks and Load Backrest.
NOTE: The reach carriage assembly must be in-
stalled on the mast before starting.

Single-Reach Scissor Arms

REMOVE AND DISASSEMBLE 3. Use a crane to support the inner scissor arm. Se-
curely attach chains or slings to the arm so that
NOTE: The reach assembly must be in the fully-ex- it cannot slip. Be careful not to damage the hose
tended position. mount sheaves.
The following procedures refer to removing the scis-
sor arms from the rear frame. See Figure 11. WARNING
The points between the scissor arms and the
rear frame are pinch points and can cause an
WARNING
injury. DO NOT put your hands near pinch
There are pinch points on the reach carriage points when removing the pivot pins. Use a
assembly that can cause an injury. Use clamps hammer and brass drift to remove the pins.
and blocks to prevent the scissor arms from
moving. Install the clamps and blocks at the 4. Remove the shoulder bolt and nut from the reach
channels of the rear frame to make sure that cylinder pins. Use a drift to drive out the cylin-
the load rollers cannot move in the channel. der rod end pins attaching the reach cylinders
See Figure 8. to the inner scissor arm. Use wire to hold each
reach cylinder and their hoses in position when
Be careful when removing or installing snap the pins are removed. Remove the bushings from
rings. These snap rings are large and can the mounts.
come loose during removal or installation with
enough force to cause an injury. Always use
the correct snap ring pliers, and wear eye and WARNING
face protection during removal or installation. The load rollers and scissor arms can move and
cause an injury when the clamps and blocks at
NOTE: Use safety chains on the rear frame and mast the load rollers are removed. Make sure the
weldments to keep the rear frame and mast weld- crane is in a position to prevent movement of
ments from moving. Install the safety chains as de- the scissor arms as the clamps and blocks are
scribed in Safety Procedures When Working Near removed.
Mast in this section.
5. Carefully remove the clamps and blocks at the
1. Remove the front frame as described in Reach load rollers on the channels of the rear frame.
Assembly Front Frame. Secure the cable guide Carefully move the scissor arms to align the load
at the rear frame to avoid damage. rollers with the removal notch in the rear frame.
Raise the crane to move the load rollers out of the
2. Remove the hydraulic components from the rear frame.
reach carriage assembly as required.

15
Single-Reach Scissor Arms 4500 SRM 1196

1. CAPSCREW 16. BUSHING

2. BELLEVILLE WASHER 17. BUSHING
3. BEARING CAP 18. PIVOT PIN
4. WASHER 19. SHOULDER BOLT
5. RH OUTER SCISSOR ARM 20. PIN
6. LH OUTER SCISSOR ARM 21. PIN
7. LOAD ROLLER AND SHIM 22. NUT
8. WEAR PLUG 23. 90° HYDRAULIC FITTING
9. LUBE FITTING 24. PIN
10. CAPSCREW 25. RH CYLINDER ASSEMBLY
11. BEARING 26. LH CYLINDER ASSEMBLY
12. SETSCREW 27. POSITION SENSOR (N35ZDR, N45ZR, N30ZDR,
13. JAM NUT N35-40ZR)
14. LOAD ROLLER AND SHIMS 28. BRACKET
15. INNER SCISSOR ARM 29. CAPSCREW

Figure 11. Single-Reach Scissor Arms

16
4500 SRM 1196 Single-Reach Scissor Arms

7. Models N35ZDR, N45ZR, N30ZDR, and

WARNING N35-40ZR have a position sensor mounted to
The scissor arms are heavy and can cause an the right side inner scissor arm pivot pin at
injury if allowed to fall. Have another person the rear frame. Remove the position sensor as
help you support the scissor arm during re- follows:
moval and installation.
a. Disconnect the wiring harness, carefully clip
NOTE: Install labels identifying scissor arm compo- the wire tie, and remove the capscrew and
nent locations and orientation for correct installa- spacer securing sensor bracket to the rear
tion. frame. The sensor can now be turned, but
the sensor shaft should still be attached to
6. Remove the three capscrews, lockwashers, and the pivot pin. See Figure 13.
end plate at the center pivot. Hold the outer scis-
sor arm and carefully slide it and the bearing off
the stub shaft. Remove the bearing assembly and
spacer. Repeat for the other side. See Figure 12.

1. INNER SCISSOR ARM

2. PIVOT PIN
3. SETSCREW
1. STUB SHAFT 4. PIN RETAINER
2. SPACER 5. SCREW
3. LH OUTER SCISSOR ARM 6. SENSOR SHAFT (FLAT TOWARD SETSCREW)
4. BEARING ASSEMBLY 7. POSITION SENSOR AND BRACKET
5. BEARING RETAINER CAP
6. BELLEVILLE WASHER Figure 13. Position Sensor
7. CAPSCREW
b. Remove the screw securing the pin retainer
Figure 12. Outer Arm and Bearing Assembly to the scissor arm and slide the pin retainer
from behind the sensor.
NOTE: Tag and identify each shim pack and the load
roller. When new load rollers are installed, the shim c. A setscrew in the pivot pin (behind the sen-
arrangement will normally be the same or similar. sor) secures the sensor shaft to the pivot pin.
Loosen the setscrew and slide the position
WARNING sensor from the pivot pin.
The points between the scissor arms and the 8. Remove the pivot pins from the inner scissor
rear frame are pinch points and can cause an arms using a hammer and a brass drift. Remove
injury. DO NOT put hands near pinch points the inner scissor arms from the rear frame.
when you remove the pins. Use a hammer and Remove the bushings from the inner arms if
brass drift to remove the pivot pins. replacement is necessary.

17
Single-Reach Scissor Arms 4500 SRM 1196

CLEAN AND INSPECT 2. Install position sensor to right pivot pin as re-
moved:
WARNING a. Check that the pin retainer hole aligns with
Cleaning solvents can be flammable and toxic mounting hole in scissor arm. Adjust to align
and can cause skin irritation. Always wear if necessary. DO NOT install the pin retainer
the proper protective equipment including at this time. See Figure 13.
eye protection and petroleum resistant gloves
when handling. Always follow the recommen- b. Remove the setscrew from the pivot pin
dations of the manufacturer. and clean old thread-lock residue from the
threads. Apply Loctite® 242 to the threads
CAUTION and start screw into the pivot pin.
DO NOT use steam to clean sealed bearings. c. Position the sensor assembly to the pivot pin
DO NOT use compressed air or immerse in sol- so that the sensor shaft enters the pin with
vent to clean sealed bearings. Sealed bearings the flat side of the shaft facing the setscrew.
are self-contained and permanently lubri- Tighten the setscrew.
cated. Wipe bearings off with a clean cloth and
turn to check for proper operation. Replace if d. Install the pin retainer onto the pivot pin and
movement is restricted or if bearing does not secure in place with screw as removed.
turn smoothly.
e. Align the sensor and mounting bracket hole
Clean all of the parts of the scissor arm assembly and install capscrew and spacer.
with solvent. Inspect the parts of the scissor arm
assembly for damage and wear. Replace all bushings f. Install wiring connector and secure harness
and load rollers. to bracket with new wire tie as removed.

ASSEMBLE AND INSTALL WARNING

The scissor arms are heavy and can cause an
Always use new bushings and load rollers. Install a
injury if allowed to fall. Have another person
thin coat of multipurpose grease on all new bushings,
help you support the scissor arm during re-
all thrust washers, all shims, all stub shafts, and all
moval and installation. NEVER put any part
pins of the scissor arm assembly. For the following
of your body between the parts of the scissor
procedures, refer to Figure 11.
arm assembly.

WARNING NOTE: Move the outer scissor arm when tightening

Use safety chains on the rear frame and mast the capscrews to make sure the bearings seat prop-
weldments to keep the rear frame and mast erly.
weldments from moving. Install the safety
3. Install the bearing assembly onto the left hand
chains as described in Safety Procedures
stub shaft of the inner scissor arms. Install the
When Working Near Mast in this section.
left hand outer scissor arm over the bearing
The points between the scissor arms and the assembly. Install the bearing cap, and align the
rear frame are pinch points and can cause an holes with the stubshaft holes. Apply Loctite®
injury. DO NOT put your hands near pinch 290 and install three capscrews and belleville
points when removing the pivot pins. Use a washers. Tighten the three capscrews to snug,
hammer and brass drift to remove the pivot then tighten each capscrew incrementally to
pins. maintain even pressure on the bearing until
each of the belleville washers are flattened.
1. Install the bushings to inner scissor arm if re- When the belleville washers are flat, the cap-
moved. Using an overhead lifting device (crane), screws are properly tightened.
raise inner scissor arm to align the mounts with
the mounts of the rear frame. Install both pivot
pins, the LH pin retainer, and screw to secure.

18
4500 SRM 1196 Single-Reach Scissor Arms

CAUTION CAUTION
DO NOT let the load rollers or shims fall off the DO NOT let the load rollers or shims fall off the
scissor arms. scissor arms.

NOTE: Correct placement of shims is critical for the 7. Install the shims and load rollers on the inner
operation of the reach mechanism. Unless the shims scissor arm weldment as marked during removal
are installed correctly, the reach mechanism will not and disassembly. If necessary, use tape to keep
operate. the load rollers on the scissor arms. Install the
hoses on the hose sheaves, and install the hose
4. Install the shim sets and load rollers on each sheaves and snap rings at the mount of the scis-
outer scissor arm as marked during removal and sor arm weldment. Refer to Figure 14.
disassembly. Install snap rings onto stub shafts
to secure. See Figure 14. 8. Install the front frame as removed. Refer to
Reach Assembly Front Frame.
5. Use the crane to slowly raise the scissor arms to
align the load rollers with the removal notches in
the rear frame. Use the crane to move the scissor
arm assembly so the load rollers move into the
channels.

6. Slowly raise the scissor arm assembly to align

the mounts with the rod ends of the reach cylin-
ders. Install the bushings, pins, and shoulder
bolt to fasten the reach cylinders to the inner scis-
sor arm. See Figure 21.

WARNING
The scissor arms are heavy and can cause an
injury if allowed to fall. Have another person
help you support the scissor arm during re-
moval and installation. NEVER put any part 1. SNAP RING 3. SHIM(S)
2. LOAD ROLLER 4. STUB SHAFT
of your body between the parts of the scissor
arm assembly. Figure 14. Load Roller Assembly

19
Double-Reach Scissor Arms 4500 SRM 1196

Double-Reach Scissor Arms

DISASSEMBLE points when removing the pivot pins. Use a
hammer and brass drift to remove the pins.
The entire scissor assembly may not need to be dis-
assembled to make repairs. Perform only the steps 5. Remove the shoulder bolt and nut from the reach
necessary to safely complete the necessary repairs. cylinder pins. Use a drift to drive out the cylin-
For the following procedures, refer to Figure 15. der rod end pins attaching the reach cylinders
to the inner scissor arm. Use wire to hold each
reach cylinder and their hoses in position when
WARNING
the pins are removed. Remove the bushings from
There are pinch points on the reach car- the mounts. See Figure 21.
riage that can cause an injury. Use clamps
and blocks to prevent the scissor arms from 6. Remove the cotter pin, castle nut, and washer
moving. Install the clamps and blocks at the from the threaded shaft on the bottom pivot
channels of the rear frame to make sure that points of outer scissor arms D and C. See Fig-
the load rollers cannot move in the channel. ure 15.
See Figure 8.

Be careful when removing or installing snap WARNING

rings. These snap rings are large and can The scissor arms are heavy and can cause an
come loose during removal or installation with injury if allowed to fall. Have another person
enough force to cause an injury. Always use help you support the scissor arm during re-
the correct snap ring pliers and wear eye and moval and installation.
face protection during removal or installation.
7. Remove the three capscrews, lockwashers, end
NOTE: Use safety chains on the rear frame and mast cap, and the spacer at the center pivot for outer
weldments to keep the rear frame and mast weld- scissor arm D. Hold outer scissor arm D and slide
ments from moving. Install the safety chains as de- it and the bearing assembly off the stub shaft.
scribed in Safety Procedures When Working Near Remove the bearing at the center pivot. Remove
Mast in this section. scissor arm C following this same procedure.

1. Remove the front frame as described in Reach 8. Slowly lower inner scissor arm A so it hangs from
Assembly Front Frame. Remove the snap rings the ends of outer scissor arms F and E. Discon-
and hose sheaves at the scissor arm weldments. nect the crane and sling from inner scissor arm
Fasten the cable and hoses at the rear frame so A and attach it securely to inner scissor arm B.
they are not damaged.
WARNING
2. Remove the hydraulic components from the
reach carriage assembly as required. The load rollers and scissor arms F and E can
shift and cause an injury when the clamps
3. Use a crane to support scissor arm weldment A. and blocks at the load rollers are removed.
Securely attach chains or slings to the weldment Make sure the crane is in a position to prevent
so that it cannot slip. Be sure not to damage the movement of the scissor arms as the clamps
hose mount sheaves. and blocks are removed.

4. Install the clamps and blocks at the channels of 9. Carefully remove the clamps and blocks at the
the rear frame to make sure the load rollers can- load rollers on the channels of the rear frame.
not move in the channel and the scissor arms can- Slowly move outer scissor arm B using the crane
not retract. See Figure 8. to align the load rollers of outer scissor arms F
and E with the removal notch in the rear frame.
See Figure 15. Use the crane to move the as-
WARNING
semblies until the load rollers are out of the rear
The points between the scissor arms and the frame. Lower the crane so the scissor arm assem-
rear frame are pinch points and can cause an bly retracts as the ends of the scissor arms move
injury. DO NOT put your hands near pinch down the outside of the channel.

20
4500 SRM 1196 Double-Reach Scissor Arms

10. Install a safety chain between the rear frame and rollers assembly and recover the shim pack from
inner scissor arm B so the scissor arm assemblies the stub shaft.
cannot extend. Reattach the crane and chains or
slings so they again support the weight of inner WARNING
scissor arm A.
The points between the scissor arms and the
11. Remove the cotter pin and castle nut from the rear frame are pinch points and can cause an
threaded shaft on the top pivot points of outer injury. DO NOT put your hands near pinch
scissor arms F and E. points when removing the pivot pins. Use a
hammer and brass drift to remove the pivot
pins.
WARNING
The scissor arms are heavy and can cause an 15. Models N35ZDR, N45ZR, N30ZDR, and
injury if allowed to fall. Have another person N35-40ZR have a position sensor mounted over
help you support the scissor arm during re- the right pivot pin at the rear frame. Remove
moval and installation. the position sensor as follows:

NOTE: This action will also release scissor arm weld- a. Disconnect the wiring harness, carefully clip
ment A. the wire tie, and remove the capscrew and
spacer securing sensor bracket to the rear
12. Remove the three capscrews, lockwashers, end frame. The sensor can now be turned, but
cap, and the spacer at the center pivot for outer the sensor shaft should still be attached to
scissor arm F. Hold outer scissor arm F and slide the pivot pin. See Figure 16.
it and the bearing assembly off the stub shaft.
Remove the bearing at the center pivot. Remove b. Remove the screw securing the pin retainer
outer scissor arm E following this same proce- to the scissor arm and slide the pin retainer
dure. from behind the sensor.

13. Use the crane to remove and lower the inner scis- c. A setscrew in the pivot pin (behind the sen-
sor arm A to the floor. Move the crane and chains sor) secures the sensor shaft to the pivot pin.
or slings again to support the weight of inner scis- Loosen the setscrew and slide the position
sor arm B. Carefully remove the safety chain. sensor from the pivot pin.

NOTE: Tag and identify the location of each shim 16. Remove the pivot pins from the scissor arms. Re-
pack and load roller. When new load rollers are in- move inner scissor arm B. Remove the bushings
stalled, the shim arrangement will normally be the from the scissor arms if replacement is necessary.
same or similar.

14. Remove the snap ring securing the load wheel to

the outer scissor arms F and E. Remove the load

21
Double-Reach Scissor Arms 4500 SRM 1196

Figure 15. Double-Reach Scissor Arms

22
4500 SRM 1196 Double-Reach Scissor Arms

Legend for Figure 15

A. INNER SCISSOR ARM (FRONT) D. OUTER SCISSOR ARM (RIGHT FRONT)
B. INNER SCISSOR ARM (REAR) E. OUTER SCISSOR ARM (LEFT REAR)
C. OUTER SCISSOR ARM (LEFT FRONT) F. OUTER SCISSOR ARM (RIGHT REAR)
1. CAPSCREW 18. BUSHING
2. BELLEVILLE WASHER 19. POSITION SENSOR (N35ZDR, N45ZR, N30ZDR,
3. BEARING CAP AND N35-40ZR)
4. FRONT FRAME PIN 20. RETAINING BRACKET AND CAPSCREW
5. CAPSCREW 21. ROD END PIN
6. BEARING ASSEMBLY 22. NUT
7. WASHER 23. SHOULDER BOLT
8. COTTER PINS 24. ROD ENDS
9. LUBE FITTING 25. CYLINDER RODS
10. BUSHING 26. LH EXTEND CYLINDER
11. SHIM 27. RH EXTEND CYLINDER
12. LOAD ROLLER ASSEMBLY 28. 90° HYDRAULIC FITTING
13. SNAP RING 29. PIVOT PIN
14. WASHER 30. CYLINDER MOUNTING PIN
15. LOAD ROLLER 31. NUT
16. WEAR PLUG AND SETSCREW 32. SHOULDER BOLT
17. JAM NUT 33. CASTLE NUT
Legend for Figure 16
1. INNER SCISSOR ARM
2. PIVOT PIN
3. SETSCREW
4. PIN RETAINER
5. SCREW
6. SENSOR SHAFT (FLAT TOWARD SETSCREW)
7. POSITION SENSOR AND BRACKET

Figure 16. Position Sensor

23
Double-Reach Scissor Arms 4500 SRM 1196

CLEAN AND INSPECT of the rear frame. Install both pivot pins, the LH
pin retaining bracket, and screw to secure.
WARNING 4. Install position sensor to right pivot pin as re-
Cleaning solvents can be flammable and toxic moved:
and can cause skin irritation. Wear protection
for eyes and skin. When using cleaning sol- a. Check that the pin retainer hole aligns with
vents, always follow the recommendations of mounting hole in scissor arm. Adjust to align
the manufacturer. if necessary. DO NOT install the pin retainer
at this time. See Figure 16.
CAUTION b. Remove the setscrew from the pivot pin
DO NOT use steam or compressed air to clean and clean old thread-lock residue from the
the load rollers. The load roller bearings are threads. Apply Loctite 242 to the threads
sealed and permanently lubricated. The air and start screw into the pivot pin.
can force the lubricant out of the bearings.
c. Position the sensor assembly to the pivot
Clean all of the parts of the scissor arm assembly pin so that the sensor shaft enters the pivot
with solvent. Dry the parts with compressed air. In- pin with the flat side of the shaft facing the
spect the parts of the scissor arm assembly for dam- setscrew. Tighten the setscrew.
age and wear. Replace all bushings and load rollers
as necessary. d. Install the pin retainer onto the pivot pin and
secure in place with screw as removed.
ASSEMBLE
e. Align the sensor and mounting bracket hole
For the following procedures, refer to Figure 15. and install capscrew and spacer.
NOTE: Use safety chains on the rear frame and mast f. Install wiring connector and secure harness
weldments to keep the rear frame and mast weld- to bracket with new wire tie as removed.
ments from moving. Install the safety chains as de-
scribed in Safety Procedures When Working Near WARNING
Mast in this section.
The scissor arms are heavy and can cause an
NOTE: Always use new bushings and load rollers. injury if allowed to fall. Have another person
Install a thin coat of multipurpose grease on all help you support the scissor arm during re-
new bushings, all thrust washers, all shims, all stub moval and installation. NEVER put any part
shafts, and all pins of the scissor arm assembly. of your body between the parts of the scissor
arm assembly.
WARNING NOTE: Move the outer scissor arm when tightening
The points between the scissor arms and the the capscrews to make sure the bearings seat prop-
rear frame are pinch points and can cause an erly.
injury. DO NOT put your hands near pinch
points when removing the pivot pins. Use a 5. Install the bearing assemblies onto each stub
hammer and brass drift to remove the pivot shaft of the inner scissor arm B. Install the outer
pins. scissor arm E over the bearing assembly. Install
the bearing cap, and align the holes with the
1. Install the bushings to inner scissor arms A and stubshaft holes. Apply Loctite® 290 and install
B if removed. three capscrews and belleville washers. Tighten
the three capscrews to snug, then tighten each
2. Install the load rollers on the stub shafts at the capscrew incrementally to maintain even pres-
end pivot of outer scissor arms F and E. Secure sure on the bearing until each of the belleville
using retaining ring and install wear plugs, washers are flattened. When the belleville
setscrews, and jam nuts. washers are flat, the capscrews are properly
tightened.
3. Using the lifting device (crane), raise inner scis-
sor arm B to align the mounts with the mounts

24
4500 SRM 1196 Double-Reach Scissor Arms

6. Attach another lifting device to inner scissor arm inner scissor arm A and inner scissor arm B
A. Move inner scissor arm A into a position of at the same time. Install the bearing cap, and
alignment to install outer scissor arm E to in- align the holes with the stubshaft holes. Apply
ner scissor arm A. Install washer and castle nut. Loctite® 290 and install three capscrews and
Torque to 115 N•m (85 lbf ft). Slightly loosen cas- belleville washers. Tighten the three capscrews
tle nut (if necessary) to align the cotter pin hole. to snug, then tighten each capscrew incremen-
Install cotter pin through the hole in the direc- tally to maintain even pressure on the bearing
tion of the forks and bend prongs to set. until each of the belleville washers are flattened.
When the belleville washers are flat, the cap-
7. Install outer scissor arm F over the bearing as- screws are properly tightened. On inner scissor
sembly on inner scissor arm B and position into arm A, install washer and castle nut. Torque to
inner scissor arm A at the same time. On in- 115 N•m (85 lbf ft). Slightly loosen castle nut
ner scissor arm B, install the bearing cap, and (if necessary) to align the cotter pin hole. Install
align the holes with the stubshaft holes. Ap- cotter pin through the hole in the direction of the
ply Loctite® 290 and install three capscrews and forks and bend prongs to set.
belleville washers. Tighten the three capscrews
to snug, then tighten each capscrew incremen-
tally to maintain even pressure on the bearing WARNING
until each of the belleville washers are flattened. The load rollers and outer scissor arms F and E
When the belleville washers are flat, the cap- can move and cause an injury when the clamps
screws are properly tightened. Install washer and blocks at the load rollers are removed.
and castle nut on inner scissor arm A. Torque to Make sure the crane is in a position to prevent
115 N•m (85 lbf ft). Slightly loosen castle nut movement of the scissor arms as the clamps
(if necessary) to align the cotter pin hole. Install and blocks are removed.
cotter pin through the hole in the direction of the
forks and bend prongs to set. 10. Slowly position the scissor arm assembly to align
the load rollers of outer scissor arms F and E
8. Install the bearing assemblies onto each stub with the removal notches in the rear frame. See
shaft of the inner scissor arm A. Use the lifting Figure 15. Use the crane to move the scissor arm
devices to position the weldments where outer assembly to guide the load rollers into the rear
scissor arm D can be installed to inner scissor frame.
arm A and inner scissor arm B at the same
time. Install the bearing cap, and align the holes 11. Install the clamps and blocks at the channels of
with the stubshaft holes. Apply Loctite® 290 the rear frame to make sure that the load rollers
and install three capscrews and belleville wash- cannot move with in the channel. See Figure 8.
ers. Tighten the three capscrews to snug, then 12. Slowly raise scissor arm assembly to align the
tighten each capscrew incrementally to main- mounts with the rod ends of the reach cylinders.
tain even pressure on the bearing until each of Install the bushings, pins, and shoulder bolts to
the belleville washers are flattened. When the fasten the reach cylinders to the inner scissor
belleville washers are flat, the capscrews are arm B.
properly tightened. On inner scissor arm A,
install the washer, castle nut, and cotter pin.

9. Use the lifting devices to position the weldments

where outer scissor arm C can be installed to

25
Rear Frame Assembly 4500 SRM 1196

Rear Frame Assembly

For the following procedures, refer to Figure 17.
WARNING
Reach carriage assemblies are heavy. Be sure
that all lifting devices are suitable and of ade-
quate 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 18.

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 carriage

assembly:
1. GREASE FITTING a. Remove the cotter pin and chain anchor pin
2. BUSHING securing the chain to the anchors. See Lift
3. WASHER
4. CAPSCREW Chains.
5. SHIM
6. SIDE ROLLER ASSEMBLY b. Secure chains to the mast using stiff wire to
7. SHIM keep them from falling from the sheaves.
8. LOAD ROLLER
9. RETAINING RING c. If the mast must be disassembled or the
10. SHIM chains need to be cleaned/lubricated, remove
the lift chains and inspect and clean.
Figure 17. Rear Frame (6.9 Mast Shown)
(N30ZDRS and N35-40ZRS) 8. Tag and disconnect the attachment hoses from
the two fittings at bottom of the rear frame of
REMOVE the reach carriage assembly. Cap or plug all open
hydraulic hoses.
NOTE: The following steps outline the procedures for
removing the reach carriage assembly from a mast, 9. Disconnect the wiring connector at the top of the
which is installed to a lift truck. rear frame. Remove the reach wiring harness.
1. Remove the forks. See Forks. NOTE: Make sure lift chains, wiring, and hoses are
secured out of the way so they do not interfere with
2. Remove the load backrest. See Load Backrest.
reach assembly removal procedures.
3. Remove the hardware securing the operator
10. Remove the safety chains and completely lower
guard from the rear of the mast, and remove the
the reach carriage assembly to the floor.
operator guard.

26
4500 SRM 1196 Rear Frame Assembly

11. Attach an overhead lifting device to the top of the

WARNING inner mast. Raise the inner mast until clearly
Mast assemblies are heavy. Be sure that all lift- higher than the reach carriage assembly. Move
ing devices are suitable and of adequate capac- the reach carriage assembly away from the lift
ity to lift the components. truck and completely lower the mast.
NOTE: Use a second lift truck or overhead lifting de- 12. Disconnect the lifting device from the reach car-
vice to move the reach carriage assembly. riage assembly.

Figure 18. Install C-Clamps to Rear Frame

27
Rear Frame Assembly 4500 SRM 1196

DISASSEMBLE
NOTE: It is usually not necessary to remove all the
parts of the rear frame assembly. Remove only the
necessary parts to do the repair.

1. If necessary, remove the reach cylinders. See

Reach Cylinders.

WARNING
Be careful when removing or installing snap
rings. These snap rings are large and can
come loose during removal or installation with
enough force to cause an injury. Always use
the correct snap ring pliers, and wear eye and
face protection during removal or installation.

2. Remove the snap rings from the stub shaft for the
load roller. See Figure 19.
1. LOAD ROLLER WITH SNAP RING REMOVED
2. PRY BAR
3. REAR FRAME

Figure 20. Removing Load Roller (6.9 Mast

Shown) (N30ZDRS and N35-40ZRS)

4. 6.9 Mast Only (N30ZDRS and N35-40ZRS) -

Remove the capscrews that fasten the side roller
brackets. Remove the side rollers and shim sets.
Install labels for correct installation of the shim
sets in the same positions. When the new side
rollers are installed, the shim arrangement will
normally be the same or similar.

NOTE: Correct placement of shims is critical for the

operation of the reach mechanism. Unless the shims
1. SNAP RING 3. SPACER are installed correctly, the reach mechanism will not
2. LOAD ROLLER 4. STUB SHAFT operate.
Figure 19. Load Roller Assembly 5. If necessary, remove the hydraulic lines and
hoses at the base of the rear frame.
3. Use a pry bar to remove the load roller from the
stub shaft for the load roller. See Figure 20.

28
4500 SRM 1196 Rear Frame Assembly

CLEAN AND INSPECT Measure and adjust the load rollers as necessary.
See Reach Assembly Adjustments.
WARNING 2. Install the scissor arms if removed. See Sin-
Cleaning solvents can be flammable and toxic gle-Reach Scissor Arms or Double-Reach Scissor
and can cause skin irritation. Always wear Arms.
the proper protective equipment including
eye protection and petroleum resistant gloves 3. 6.9 Mast Only (N30ZDRS and N35-40ZRS) -
when handling. Always follow the recommen- Install the side rollers as removed. Measure and
dations of the manufacturer. adjust the side rollers as necessary. See Reach
Assembly Adjustments.
CAUTION 4. If the rod ends of the reach cylinders were re-
DO NOT use steam to clean sealed bearings. moved, the reach cylinders must be adjusted
DO NOT use compressed air or immerse in sol- after the reach assembly is completely assem-
vent to clean sealed bearings. Sealed bearings bled and installed in the mast. See Adjust Reach
self-contained and permanently lubricated. Cylinders, Reach Assembly Adjustments.
Wipe bearings off with a clean cloth and turn
to check for proper operation. Replace if INSTALL
movement is restricted or if bearing does not
turn smoothly. NOTE: Use a second lift truck or overhead lifting de-
vice to move the reach carriage assembly.
Clean all of the parts of the rear frame with solvent.
Dry the parts with compressed air. Inspect the parts 1. Position the reach carriage assembly in an up-
of the rear frame for damage and wear. Inspect all right position in front of the mast. Align the load
rollers for cracks, flat spots, or bearings that do not rollers on the rear frame of the reach carriage as-
turn freely. Replace any roller that shows wear or is sembly with the inner mast.
damaged.
WARNING
ASSEMBLE
Mast assemblies are heavy. Be sure that all lift-
ing devices are suitable and of adequate capac-
WARNING ity to lift the components.
Be careful when removing or installing snap
rings. These snap rings are large and can NOTE: Use an overhead lifting device of suitable ca-
come loose during removal or installation with pacity to raise the inner mast when installing the
enough force to cause an injury. Always use reach carriage assembly. Use second lift truck to po-
the correct snap ring pliers, and wear eye and sition the reach carriage assembly.
face protection during removal or installation.
2. Raise the inner mast until clearly higher than
the reach carriage assembly. Position the reach
WARNING carriage assembly so the load rollers on the rear
The rear frame assembly is heavy and can frame are centered under the channels of the in-
cause an injury if it tips or falls. Make sure the ner mast.
rear frame assembly is stable before installing
any parts. 3. Lower the inner mast channels onto the load
rollers of the rear frame. If the inner mast does
NOTE: If the scissor arms are not installed, install not lower smoothly and completely, raise the
the rear frame in the mast before installing the scis- inner mast, reposition the reach carriage assem-
sor arm assembly. See Install. bly, and lower the inner mast again.
1. Install the load roller on to the rear frame.
Install shims in the same location as removed.

29
Reach Cylinders 4500 SRM 1196

8. Connect the wiring connector and install the

WARNING mounting plate to the top of the rear frame.
Reach carriage assemblies are heavy. Be sure
that all lifting devices are suitable and of ade- 9. Remove caps/plugs from the attachment hoses
quate capacity to lift the components. and fittings. Reconnect the hoses as removed.

4. Attach an overhead lifting device to the top of the 10. Remove the safety chains and completely lower
reach carriage assembly: the reach carriage assembly.

a. Install heavy-duty, industrial C-clamps to 11. Remove the C-clamps and lifting device from the
each side of the rear frame. See Figure 18. reach carriage assembly.

b. Install a chain loop or sling through each 12. Raise and lower the mast several times to remove
clamp separately, and attach each loop to the air from the system. Cycle the sideshift function
overhead lifting device. several times to remove air from the sideshift cir-
cuit, if so equipped. Check for proper operation.
5. Raise the reach carriage assembly high enough
to access the hydraulic connections and wiring 13. Check the hydraulic oil level and add as required.
harness mounting plate on the rear frame.
14. Check reach carriage assembly height and align-
6. Safety chain the reach carriage assembly in ment and adjust the lift chains as required. See
place. See Safety Procedures When Working Reach Assembly Adjustments.
Near Mast.
15. Install the load backrest. See Load Backrest.

CAUTION 16. Install the forks. See Forks.

If reusing chains, make sure chains have been
properly inspected, cleaned, and lubricated. 17. Install the operator guard as removed.
See Lift Chains.

7. Reconnect the lift chains to anchors on reach car-

riage assembly as removed. Install anchor pins
and cotter pins.

Reach Cylinders
REMOVE 1. Operate the LIFT/LOWER control handle to
raise the reach assembly for access to the reach
For the following procedures, refer to Figure 21. cylinders from the operator compartment of the
lift truck.
CAUTION
2. Remove the operator guard from the rear of the
DO NOT operate any functions if the front mast.
frame has been removed. Hydraulic oil can
come out of the hoses. 3. Install labels on the hydraulic lines for correct
connection during installation. Disconnect the
NOTE: Fully extend the reach mechanism. If the hydraulic lines at the reach cylinders. Install
scissor arms and front frame are installed, use caps on the hydraulic lines and cylinder ports to
clamps and blocks to prevent the scissor arms from prevent dirt from entering the system. Check the
retracting. Install the clamps and blocks on the hydraulic fittings for damage. Replace as neces-
channels of the rear frame and the front frame. In- sary.
stall the blocks under the load rollers. See Figure 22.
4. Remove nuts and capscrews from each cylinder
Tighten the clamps so the blocks cannot move. rod end. Remove pins from rod ends and mast by
tapping out with a drift.

30
4500 SRM 1196 Reach Cylinders

1. INNER SCISSOR ARM 9. REACH CYLINDER

2. GREASE FITTING 10. HYDRAULIC FITTING
3. ROD END 11. RETRACT HOSE
4. NUT 12. HYDRAULIC FITTING
5. CAPSCREW 13. EXTEND HOSE
6. BUSHING 14. NUT
7. PIN 15. PIN
8. CAPSCREW 16. CAPSCREW

Figure 21. Reach Cylinder Mounting

31
Reach Cylinders 4500 SRM 1196

NOTE: If disassembly of a reach cylinder is neces-

sary, loosen the retainer in the cylinder shell while
the cylinder is installed in the reach assembly. It
is possible that reach adjustments will not be nec-
essary. If disassembly is NOT necessary and the rod
ends will NOT be replaced, mark the reach cylinders
for installation in the same position.

5. Mark each rod end of the reach cylinders for cor-

rect installation. The RH and LH reach cylinders
are not interchangeable.

6. Have a helper hold the reach cylinder to keep it

from falling. Use a drift to remove the pins that
fasten each end of cylinder to the frame. Remove
the other reach cylinder using the same proce-
dure.

7. Remove the bushings from each mount of the

rear frame and each scissor arm.

1. REAR FRAME 3. BLOCK

2. LOAD ROLLER 4. CLAMP

Figure 22. Block and Clamp Installation

32
4500 SRM 1196 Reach Cylinders

DISASSEMBLE
For the following procedures, refer to Figure 23.

1. LOCK NUT 7. O-RING

2. PISTON RINGS 8. BACKUP RING
3. PISTON PACKING 9. ROD SEAL
4. PISTON 10. WIPER RING
5. CYLINDER TUBE 11. PACKING GLAND
6. PISTON ROD

Figure 23. Reach Cylinder Parts

NOTE: In most instances, it is more cost effective to for eyes and skin. When using cleaning sol-
simply replace the reach cylinders with a whole new vents, always follow the recommendations of
unit than to repair them. the manufacturer.

NOTE: Take care not to scratch the cylinder rod dur-

ing the repair process. CAUTION
DO NOT operate any functions if the front
1. Loosen the capscrew at the rod end. Hold the rod frame has been removed. Hydraulic oil can
to keep it from turning and remove the rod end come out of the hoses.
from the cylinder rod.
Clean all of the parts of the reach cylinder with sol-
2. Carefully remove the retainer and rod assembly vent. Dry the parts with compressed air. Inspect the
from the cylinder shell. parts of the reach cylinder for damage and wear. Re-
place all parts that are worn or damaged. Replace all
3. Carefully remove the parts of the rod assembly. parts included in the cylinder repair kit.

CLEAN AND INSPECT

WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. Wear protection

33
Tilt Cylinder 4500 SRM 1196

ASSEMBLE the rear frame. Use a hammer with a soft metal

(brass or copper) or a plastic face to install the
1. Install the parts of the rod assembly as shown pins.
in Figure 23. Make sure to replace all seals and
other parts included in the cylinder repair kit. 3. Connect the hydraulic lines to the reach cylin-
Use Loctite® No. 242 on the rod and nut for the ders as marked during removal. Always use new
piston. Install the piston seal and piston rings. O-rings on the O-ring fittings.
If removed, tighten the piston nut to 95 N•m
(70 lbf ft). 4. Hold each reach cylinder to align the rod end to
the scissor arm mounts. Use a hammer with a
soft metal (brass or copper) or a plastic face to in-
CAUTION stall the mount pins to fasten the rod end of each
DO NOT cut or damage seals during installa- reach cylinder. Align the holes for the shoulder
tion. Be especially careful when moving seals bolt and nut. Install the shoulder bolt and nut.
across threads or edges of parts. Install tape
over the rod threads to protect the seals. NOTE: If the rod ends were not removed and the
cylinders are installed in the same positions, reach
2. Install the rod seal, backup ring, O-ring, and adjustment is normally not necessary.
wiper on the retainer. Put a thin coat of hydraulic
fluid on the inside of the shell and all parts of the 5. If the rod ends were NOT removed, install the
piston and rod. Use O-ring lubricant and install shoulder bolt and nut at each mount pin. If the
the rod assembly in the shell. Carefully install rod ends were removed, reach adjustment IS nec-
the retainer on the rod and in the shell. Use a essary. Make sure the adjustment is complete be-
spanner wrench to tighten the retainer to 129 to fore installing the shoulder bolt and nut.
142 N•m (95 to 105 lbf ft).
6. Make sure the hydraulic fittings are tightened,
INSTALL and remove the clamps and blocks under the load
bearings.
NOTE: It may be necessary to loosen the hydraulic
fittings to allow movement of the rods. The rods need
CAUTION
to move for correct alignment at the mounts for the
scissor arms. DO NOT operate any functions if the front
frame has been removed. Hydraulic oil can
1. If removed, install the correct rod end on the rod come out of the hoses.
as marked during removal. Install new bushings
in all four mounts for the reach cylinders. Lubri- 7. Operate the REACH control lever to operate the
cate the bushings with multipurpose grease. function to check for leaks and correct operation.

2. Align the anchor end of the cylinders on the cylin- 8. Remove the air from the system and adjust the
der mount of the rear frame of the reach assem- stroke of each reach cylinder as described in
bly. See Figure 21. Install the mount pins and Reach Assembly Adjustments.
shoulder bolt and nut to fasten the cylinders to

Tilt Cylinder
REMOVE NOTE: If the front frame is installed on the scissor
arms, fully extend the reach mechanism. Use clamps
The tilt cylinder is removable as an assembly. The and blocks to prevent the scissor arms from retract-
cylinder block is mounted to the front frame. If the ing. Install the clamps and blocks on the channels
cylinder block is damaged, it can be removed and of the rear frame and the front frame. Install the
replaced. See Reach Assembly Front Frame, Dis- clamps and blocks under the load bearings. See Fig-
assemble (With Sideshift) or Disassemble (Without ure 8. Tighten the clamps so the blocks cannot move.
Sideshift) in this section.

34
4500 SRM 1196 Tilt Cylinder

CLEAN, INSPECT, AND REPAIR Replace all parts included in the cylinder repair kit.
Seals and O-rings may become brittle and lose elas-
ticity over time even when the old parts show no ap-
WARNING
parent damage. See Figure 24. Clean all of the parts
Cleaning solvents can be flammable and toxic of the tilt cylinder with solvent. Dry the parts with
and can cause skin irritation. Wear protection compressed air. Inspect the parts of the tilt cylinder
for eyes and skin. When using cleaning sol- for damage and wear. Replace all parts that are worn
vents, always follow the recommendations of or damaged. Replace all parts included in the cylin-
the manufacturer. der repair kit. Use hydraulic oil to lubricate the new
Cylinder components can be disassembled to repair seals and O-rings when installing. Be careful not to
the seals if damaged. Consult the Parts Manual to damage new seals and O-rings when installing.
select the proper cylinder repair kit for your truck.

1. NUT 8. WIPER RING

2. TILTING FRAME 9. SEAL
3. WASHER 10. ROD
4. WASHER 11. BLOCK
5. SEAL 12. BUSHING
6. PISTON 13. FRONT FRAME
7. SEAL

Figure 24. Tilt Cylinder

35
Front Selector Valve 4500 SRM 1196

INSTALL
Install tilt cylinder into front frame as removed.
Refer to Reach Assembly Front Frame, or Assemble
(With Sideshift) in this section.

Sideshift Cylinder
REPAIR
The sideshift cylinder is not removable as an assem-
bly. The cylinder shell is an integral part of the tilt-
ing frame. If the cylinder shell repair is necessary,
prior approval from Hyster® Company is required.
If repair is not an option, the tilting frame must be
replaced. Refer to Front Frame With Sideshifter.

The sideshift cylinder components can be disassem-

bled to repair the seals if damaged. Check the wear
strips on the tilting frame when the fork carriage is
removed. Replace as necessary. Consult the Parts
Manual to select the proper cylinder repair kit for
your truck. Replace all parts included in the cylin-
der repair kit. Seals and O-rings may become brittle
and lose elasticity over time even when the old parts
show no apparent damage. See Figure 25. 1. WEAR STRIP 6. SLEEVE
2. WEAR STRIP 7. SEAL
3. ROD 8. TILTING FRAME
4. WIPER RING 9. LUBE FITTING
5. SEAL

Figure 25. Sideshift Repair

Front Selector Valve

The front selector valve is located in the front frame CAN module controls the front selector valve by re-
of the reach carriage. It is secured to a cover plate ceiving CAN communication signals from the truck
with three capscrews. The remote CAN module is control system and operating the electro-hydraulic
mounted below the front selector valve on the cover solenoid valves in the front selector valve. The
plate. The cover plate is mounted to the front of the remote CAN module receives these signals through
front frame, just above the tilting frame. See Fig- a wiring harness, which runs to the front frame
ure 26. inside the hose guard along side the hydraulic hoses
and activating the electro-hydraulic valves in the
The front selector valve is an electro-hydraulic valve selector valve. See Figure 27.
block that directs hydraulic flow to the tilt and
sideshift cylinders (where applicable). The remote

36
4500 SRM 1196 Front Selector Valve

1. TILT (DOWN)
2. TILT (UP)
3. SIDESHIFT (EXTEND RIGHT)
4. SIDESHIFT (EXTEND LEFT)

Figure 27. Front Selector Valve

1. FRONT SELECTOR VALVE
2. REMOTE CAN MODULE (N35ZDR, N45ZR,
N30ZDR, AND N35-40ZR ONLY)
3. BRACKET
4. COVER

Figure 26. Front Frame

37
Rear Selector Valve 4500 SRM 1196

Rear Selector Valve

The rear selector valve is mounted inside the top of valve block that directs hydraulic flow to the reach
the rear frame with three capscrews. A cover mounts cylinders and supplies the front frame (front selector
to the front side of the valve and shields it from expo- valve) hydraulics. See Figure 28.
sure. The rear selector valve is an electro-hydraulic

1. REACH CYLINDER (LH) 6. LINE

2. REACH CYLINDER (RH) 7. HOSE GUARD
3. SUPPLY LINE 8. FRONT SELECTOR VALVE
4. RETURN LINE 9. REAR SELECTOR VALVE
5. LINE

Figure 28. Reach Carriage Hydraulics

38
4500 SRM 1196 Reach Assembly Adjustments

Reach Assembly Adjustments

CHECK ADJUSTMENT assembly. If the lift chains are loose, operate
the lift button to raise the free-lift cylinder just
Check the adjustment of the reach assembly to en- enough that the lift chains are supporting the
sure proper operation of the reach assembly, mast, weight of the reach assembly. See Figure 29.
and carriage. If the reach assembly has been re-
moved, always check the condition and adjustment 2. Check between the inside of the inner mast
of the load rollers and side rollers on the rear frame channels and the load roller at the top of the
before reinstalling the reach assembly. See Adjust rear frame. Clearance should be approximately
Side Rollers and Load Rollers. 0.5 mm (0.02 in.) with the reach assembly par-
allel to the channels.
1. Fully lower the reach assembly. Make sure the
lift chains are supporting the weight of the reach

A. TWO-STAGE B. THREE-STAGE
1. INNER WELDMENT 7. SNAP RING
2. CHAIN SHEAVE 8. OUTER WELDMENT
3. LIFT CHAIN 9. ADJUSTMENT NUT
4. COTTER PIN 10. REACH ASSEMBLY
5. ANCHOR PIN 11. TYPICAL FIXED ANCHOR
6. CHAIN ANCHOR 12. INTERMEDIATE WELDMENT

Figure 29. Main Lift Chain Adjustment

39
Reach Assembly Adjustments 4500 SRM 1196

3. Raise and lower the reach assembly with a load.

Check that there is minimum clearance with
free movement. If the reach assembly does not
move smoothly during lowering, remove the
reach assembly and adjust the side rollers and
load rollers.

ADJUST SIDE ROLLERS AND LOAD

ROLLERS
NOTE: Side rollers are used only on 6.9 inch mast
carriages.

1. Measure the width between the outside edges of

the inner weldment in several places. Make a
note of the location and the value of the maxi-
mum measurement. See Figure 30.

2. Measure and record the distance between the

outside of the side rollers and load rollers of the
reach assembly. See Figure 31.

3. If the difference between dimension A and the

largest measurement between the inner mast
weldments is more than 4 mm (0.16 in.), in-
stall shims to the side rollers and/or load rollers
evenly. If the difference is less than 4 mm
(0.16 in.), remove shims from the side rollers
and/or load rollers evenly.

Figure 30. Measuring Channel Width

40
4500 SRM 1196 Reach Assembly Adjustments

1. Cycle the reach system several times to remove

air from the system. Operate the reach mecha-
nism to fully extend and retract the forks for sev-
eral cycles to check for proper operation.

2. Fully extend the forks, move the key to the OFF

position, and disconnect the battery. Measure
the distance between the contact surface of the
rear frame and the stops on the front frame.
Measure the distance on both sides. The correct
distance for a single-reach unit is 610 +3 6 mm
(24 +0.12 0.24 in.). The correct distance for a
double-reach unit is 1067 +3 6 mm (42 +0.12
0.24 in.).

3. If the distance is not within specifications on both

sides, loosen the capscrews at the rod ends of the
reach cylinders. Use a wrench on the wrench
flats to rotate the cylinder rods for adjustment.
Temporarily tighten the capscrews.

4. Operate the reach mechanism through several

cycles and fully extend the forks. Move the key
to the OFF position and disconnect the battery.
Figure 31. Side and Load Roller Widths
Measure the distance on each side again. Both
measurements must be within specifications
ADJUST REACH CYLINDERS
AND the measurements must be within 3 mm
NOTE: The reach cylinders must be adjusted if either (0.12 in.) of each other. If the measurements
reach cylinder has been replaced or the rod ends have are not within specifications, repeat Step 3 and
been removed. Adjustment is also necessary if major Step 4 until all measurements are correct. Tem-
parts of the reach mechanism have been replaced. porarily tighten the capscrews without moving
the rods after all measurements are correct.
The reach cylinders must be adjusted so the assem-
bly can fully extend to its maximum stroke. It must 5. Fully retract the forks and check each stop on the
also be adjusted to lightly touch the stops on the rear front frame. The rear frame must be touching the
frame with the cylinders fully retracted. Both cylin- stop pads.
ders must be adjusted equally to avoid a condition
6. Extend the reach mechanism, move the key to
known as racking. When racking occurs, one side of
the OFF position, and disconnect the battery.
the reach assembly is being pushed or pulled ahead
Add or remove shims under each stop pad as nec-
of the other. This can cause excessive stress on com-
essary. DO NOT use more than 3/8-in. shims.
ponents of the reach assembly resulting in erratic
Repeat Step 5 and Step 6 until the front frame
movement and premature wear.
touches on both sides.

WARNING 7. Fully extend the forks, move the key to the OFF
The points between the scissor arms and the position, and disconnect the battery. Loosen the
rear frame/front frame are pinch points and capscrews at the rod ends of the reach cylinders.
can cause an injury. DO NOT put any part of Use a wrench to rotate the cylinder rods 1/4 turn
your body between these assemblies if they clockwise into the cylinder. This adjustment al-
can move. Always move the key to the OFF lows the stop pads to absorb the shock instead of
position and disconnect the battery. the reach cylinders as the mechanism retracts.
Tighten the rod end capscrews to 35 to 40 N•m
(26 to 30 lbf ft).

41
Lift Chains 4500 SRM 1196

Lift Chains
INSPECT

WARNING
Never replace only the worn section of a chain.
Replace the complete chain. Never replace
only one chain of a chain pair. Replace both
chains.

CAUTION
Lift chains, which were not checked before
removal, must be checked for correct length
again once installed in the mast and the mast
installed on the lift truck.

NOTE: The chains must be inspected in the area of

chain that passes over the chain sheave during the
first portion of a lift. Those links will show maximum
wear.

Inspect the lift chains for wear or damage. A lift Pitch Total Length
chain becomes longer when it is worn. If a chain is Wear Limit
of 20 Links
3% longer than a new lift chain, the lift chain must be Maximum of
(Pitch) of
replaced. If a chain scale is available, check the lift 20 Links
New Chain
chain as shown in Figure 32. If a chain scale is not
available, measure 20 links of the lift chain. Com- 25.4 mm 508 mm 523 mm
pare the measurement with the lengths given in Fig- (1.00 in.) (20.0 in.) (20.6 in.)
ure 32.
31.8 mm 635 mm 654 mm
(1.25 in.) (25.0 in.) (25.7 in.)
38.1 mm 762 mm 785 mm
(1.50 in.) (30.0 in.) (30.9 in.)
44.5 mm 889 mm 915 mm
(1.75 in.) (35.0 in.) (36.0 in.)
50.8 mm 1016 mm 1047 mm
(2.00 in.) (40.0 in.) (41.2 in.)
NOTE: The instructions for measuring chain wear
are shown on the Chain Wear Scale.

1. CHAIN WEAR SCALE

Figure 32. Lift Chains Check

42
4500 SRM 1196 Lift Chains

CLEAN AND LUBRICATE a. If the tension is not the same, adjust the nuts
on the chain anchors until the tension is the
WARNING same, and tighten the lock nuts. Recheck
that the top of the weldments are still within
Cleaning solvents may be flammable and toxic
specification. See Step 1.
and can cause severe skin irritation. When
using cleaning solvents, always follow the b. If the tension on both chains are equal, pro-
solvent manufacturer’s recommended safety ceed to the next step.
precautions.
3. Adjust the free-lift chains. See Adjust Free-Lift
Always wear protective clothing and eye pro- Chains.
tection when working with compressed air.
4. Check the mast operation.
CAUTION 5. Install the mast operator guard (if removed).
DO NOT use steam to clean lift chains, sheaves,
or load rollers. The bearings in the sheaves and ADJUST FREE-LIFT CHAINS
load rollers are sealed and lubricated.
NOTE: Make sure the forks of the reach carriage are
Clean the lift chains by soaking in solvent for 30 min- parallel to the floor (no forward or backward tilt). See
utes and remove all dirt and grease. Hang lift chains Figure 32. The main lift chains must be adjusted
over a drip pan and let drip. Remove residual solvent BEFORE adjusting the free-lift chains.
using compressed air. Lubricate the chains by soak-
ing them in SAE 30 engine oil for 30 minutes. Hang 1. Fully lower the carriage. With the forks level
chains over a drip pan for one hour to remove excess (parallel to the floor), measure the distance from
oil. the floor to the top of forks. The correct distance
is 63.5 mm (2.5 in.).
ADJUST MAIN-LIFT CHAINS
2. If the distance is correct, the free-lift chains are
The main lift chains must be adjusted BEFORE ad- adjusted for the correct height. Perform Step 5
justing the free-lift chains. next. If the distance is NOT correct, perform all
of the steps.
Adjust chain anchors at main lift cylinders so top of
inner mast weldment is even with top of outer mast 3. Raise the mast until the free-lift cylinder chain
weldment. anchors at the rear of the free-lift cylinder can be
accessed from the operator compartment. Install
NOTE: Remove the mast operator guard if adjust- safety chains as described in Safety Procedures
ment is necessary. When Working Near Mast. Remove the mast op-
erator guard for easier access to the chain an-
1. Completely lower the mast. Check to verify that chors. Loosen both lock nuts at the chain anchors
the top of the outer weldment is even (±1.5 mm to make any adjustments.
(0.06 in.)) with the top of the inner mast.
4. Adjust the nuts of the chain anchors equal
a. If the top of the weldments are not even, amounts for the correct distance (Step 1).
adjust the nuts on the chain anchors until
the weldments are even, and tighten the lock 5. Check chain tension by pushing on both chains
nuts. at the same time. If the tension is not the same,
adjust the nuts on the chain anchors until the
b. If the top of the weldments are even (within tension is the same and the distance (Step 1) is
specification), proceed to the next step. also correct. When the tension is equal on both
2. Check chain tension by pushing on both main-lift chains, the chain sheave assembly will be level.
chains at the same time. Tighten the lock nuts.

43
Lift Chains 4500 SRM 1196

CAUTION
When the chain adjustments are complete,
make sure the cotter pin at the bottom of the
chain anchor can be installed under the ad-
justment nut. If there is no room to install
the cotter pin, the chains are too short. Make
sure the lock nuts on the chain anchors are
tight against the mount plate. If there are
not enough threads on the chain anchor for
correct adjustment, new chains are too long or
old chains are too worn.

6. Check the mast operation.

7. Recheck the distance from the floor to the top of

the forks.

8. Raise the reach carriage to the top of the inner

mast. Check to ensure the reach carriage stops
before hitting the stops at the top of the inner
weldment. If the reach mechanism reaches the
stops prior to full elevation, recheck fork height
with the mast fully lowered. See Step 1.

9. Extend the mast fully to check the maximum

fork height (MFH). The MFH specifications are
stamped into the side of the outer mast. With the
forks level (parallel to the floor), verify MFH by
measuring from the floor to the top of the forks
with the mast fully extended. See Figure 33.

10. Install the mast operator guard if removed.

1. REACH CARRIAGE STOP

2. MAXIMUM FORK HEIGHT (MFH)
3. FLOOR LEVEL

Figure 33. Maximum Fork Height (MFH)

44
4500 SRM 1196 Specifications

Specifications
Table 1. General Specifications

Action Specification
Load Backrest Capscrews, Torque 203 N•m (150 lbf ft)
Scissor Arms, Torques
Center Pivot Capscrews 41 N•m (30 lbf ft)
End Pivot Capscrews (Double Reach Only) 39 N•m (29 lbf ft)
Reach Cylinder, Torques
M8 Bolt 34 N•m (25 lbf ft)
Reach Mechanism
Reach Cylinder Stroke +6.4/ 9.6 mm (+0.25/ 0.38 in.)
Reach Assembly Travel
Single Reach 610 mm (24 in.)
Double Reach 1067 mm (42 in.)

45
Specifications 4500 SRM 1196

Table 2. Operating Times

Voltage Action Time

24V Fast Reach Time, Minimum Load [ 0 kg (0 lb)] 2.7 to 3.5 sec. 3.7 to 4.5 sec.
Fast Reach Time, Maximum Load [ 2041 kg (4500 lb)] 3.2 to 4.0 sec. 4 to 5 sec.
Slow Reach Time, Minimum Load [ 0 kg (0 lb)] 6 to 8 sec. 6 to 8 sec.
Tilt Time, Minimum Load [ 0 kg (0 lb)] 1.5 to 2.5 sec. 1.5 to 2.5 sec.
Tilt Time, Maximum Load [ 2041 kg (4500 lb)] 2 to 3 sec. 2 to 3 sec.
Sideshift per 3" Travel Time, Minimum Load [ 0 kg (0 lb)] 1.5 to 2.5 sec. 1.5 to 2.5 sec.
Sideshift per 3" Travel Time, Maximum Load [ 2041 kg 2 to 3 sec. 2 to 3 sec.
(4500 lb)]
Sideshift per 7" Travel Time, Minimum Load [ 0 kg (0 lb)] 3.5 to 4.5 sec. 3.5 to 4.5 sec.
Sideshift per 7" Travel Time, Maximum Load [ 2041 kg 4 to 5 sec. 4 to 5 sec.
(4500 lb)]
36V Fast Reach Time, Minimum Load [ 0 kg (0 lb)] 2.7 to 3.5 sec. 3.7 to 4.5 sec.
Fast Reach Time, Maximum Load [ 1361 kg (3000 lb)] 3.2 to 4.0 sec. 4 to 5 sec.
Slow Reach Time, Minimum Load [ 0 kg (0 lb)] 6 to 8 sec. 6 to 8 sec.
Tilt Time, Minimum Load [ 0 kg (0 lb)] 1.5 to 2.5 sec. 1.5 to 2.5 sec.
Tilt Time, Maximum Load [ 2041 kg (4500 lb)] 2 to 3 sec. 2 to 3 sec.
Sideshift per 3" Travel Time, Minimum Load [ 0 kg (0 lb)] 1.5 to 2.5 sec. 1.5 to 2.5 sec.
Sideshift per 3" Travel Time, Maximum Load [ 2041 kg 2 to 3 sec. 2 to 3 sec.
(4500 lb)]
Sideshift per 7" Travel Time, Minimum Load [ 0 kg (0 lb)] 3.5 to 4.5 sec. 3.5 to 4.5 sec.
Sideshift per 7" Travel Time, Maximum Load [ 2041 kg 4 to 5 sec. 4 to 5 sec.
(4500 lb)]
Fork Tilt Angle (Truck Level ±1°)
Down 3° ±1°
Up 4° ±1°
Fork Height, Fully Lowered (no tilt) 64 mm (2.50 in.)
Operating Pressures and Amperes (Measured at pump, ±10% acceptable)

46
4500 SRM 1196 Specifications

Table 2. Operating Times (Continued)

Voltage Action Time

Relief 24 V 16,547.4 kPa 175 Amps
(2400 psi)
36 V 16,547.4 kPa 112 Amps
(2400 psi)
Reach No Load 24 V 7584 kPa 90 Amps
(1100 psi)
Capacity Load 24 V 7584 kPa 90 Amps
(1100 psi)
No Load 36 V 7584 kPa 60 Amps
(1100 psi)
Capacity Load 36 V 7584 kPa 60 Amps
(1100 psi)
Retract No Load 24 V 11,721 kPa 127.5 Amps
(1700 psi)
Capacity Load 24 V 11,721 kPa 142.5 Amps
(1700 psi)
No Load 36 V 11,721 kPa 85 Amps
(1700 psi)
Capacity Load 36 V 11,032 kPa 95 Amps
(1600 psi)
Tilt Forward No Load 24 V 9191 kPa 97.5 Amps
(1333 psi)
Capacity Load 24 V 5688 kPa 81 Amps
(825 psi)
No Load 36 V 9191 kPa 65 Amps
(1333 psi)
Capacity Load 36 V 5688 kPa 54 Amps
(825 psi)
Tilt Backward No Load 24 V 3916 kPa 73.5 Amps
(568 psi)
Capacity Load 24 V 14,527 kPa 175.5 Amps
(2107 psi)
No Load 36 V 3916 kPa 49 Amps
(568 psi)
Capacity Load 36 V 14,527 kPa 117 Amps
(2107 psi)

47
Troubleshooting 4500 SRM 1196

Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

The forks will not extend, Wiring disconnected or damaged. Check dash display for error mes-
tilt, or sideshift. sages.
Check that all connectors are tight
and the mast cable is not damaged.

Auxiliary motor not operating. Use dash display diagnostics to check

auxiliary motor RPM.
Replace defective motor.

Control handle not operating prop- Use dash display diagnostics to check
erly. operation of handle switches. Repair
and replace as required.

Selector valve is damaged or not op- Check for correct signals from Re-
erating. mote CAN Module to the selector
valve.
Clean, repair, or replace selector
valve or valve components.

Auxiliary relief valve not operating Check for an open valve at the auxil-
properly. iary pump.
Clean, repair, or replace valve as nec-
essary.

The forks reach/retract Binding in the carriage mechanism. Ensure the mechanism moves freely.
slowly. Check for failed bearings in the
mechanism.

Reduced hydraulic flow to the reach/ Use dash display diagnostics to check
retract cylinders. auxiliary motor RPM.
Ensure parameter settings are cor-
rect.
Check the auxiliary pump for flow.
Replace pump if motor operates and
there is low flow from the pump.

Hydraulic fluid level is low. Check Fill as necessary.

levels.

48
4500 SRM 1196 Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Sideshift operation is slow. Reduced hydraulic flow to the Use dash display diagnostics to check
sideshift cylinder. auxiliary motor RPM.
Ensure parameter settings are cor-
rect.
Check the auxiliary pump for flow.
Replace pump if motor operates and
there is low flow from the pump.

Sideshift cylinder is worn or dam- Repair or replace sideshift cylinder.

aged.

Tilt operation is slow. Reduced hydraulic flow to the tilt Use dash display diagnostics to check
cylinder. auxiliary motor RPM.
Ensure parameter settings are cor-
rect.
Check the auxiliary pump for flow.
Replace pump if motor operates and
there is low flow from the pump.

Tilt cylinder is worn or damaged. Repair or replace tilt cylinder.

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 TECHNICAL PUBLICATIONS

4500 SRM 1196 7/13 (10/07)(2/07)(11/06)(10/06) Printed in U.S.A.