the best service repair manual

1. SERVICE REPAIR
N35ZRS N40ZRS N30ZDRS [A265]

2. 8000 SRM 1198 Oil Capacities
Lubrication Specifications
Application
Lubrication
Type Standard Cold Storage/Freezer Arctic
Hydraulic Oil
ISO VG 46 Antiwear
(HCE-140)
Exxon Univis® HVI 26 Exxon Univis® HVI 26
Grease
Multipurpose (Lithium
Complex) Grease
Multipurpose (Lithium
Complex) Grease
Mobilgrease® 28 Synthetic
Extra-Protection Grease
Gear Oil
80W-90 (GL-5)
Conventional Gear Oil
80W-90 (GL-5)
Conventional Gear Oil
75W-90 (GL-5) Synthetic
Gear Oil
Antiseize
Antiseize Lubricant
(MIL-A-706)
Antiseize Lubricant
(MIL-A-706)
Antiseize Lubricant
(MIL-A-706)
Oil Capacities
Hydraulic System
Truck Models
Battery Compartment
Size
Tank (Full Capacity) Usable Oil
368.0 mm
(14.5 in.)
27.0 liter
(28.5 qt)
19.6 liter
(20.7 qt)
419.0 mm
(16.5 in.)
27.0 liter
(28.5 qt)
19.6 liter
(20.7 qt)
470.0 mm
(18.5 in.)
27.0 liter
(28.5 qt)
19.6 liter
(20.7 qt)
N30ZDR, N35ZDR, N35ZR,
N40ZR, N45ZR
546.0 mm
(21.5 in.)
30.7 liter
(32.4 qt)
23.8 liter
(25.1 qt)
368.0 mm
(14.5 in.)
27.0 liter
(28.5 qt)
19.6 liter
(20.7 qt)
N30ZDRS, N35ZRS,
N40ZRS 419.0 mm
(16.5 in.)
27.0 liter
(28.5 qt)
19.6 liter
(20.7 qt)
Master Drive Unit
Truck Models Drive Type Oil Capacity
N30ZDR, N35ZR, N40ZR,
N30ZDRS, N35ZRS, N40ZRS
GK20 MDU 2.5 liter (2.6 qt)
N35ZDR, N45ZR GK25 MDU 3.7 liter (3.9 qt)
1

3. Hydraulic System 8000 SRM 1198
Hydraulic System
N30ZDR, N35ZDR, N35ZR, N40ZR, and N45ZR
Hydraulic System Motor
Pump
Displacement
Speed
(RPM)
Max Pump
Pressure
36V 25.00cc 105 to 3300
20.68 MPa
(3000 psi)
36V
Hi Performance
28.00cc 105 to 3300
20.68 MPa
(3000 psi)
Main Lift Pump and Motor
36V - EE 20.00cc 105 to 3300
20.68 MPa
(3000 psi)
Auxiliary Pump and Motor 24V/36V 2.08cc 600 to 3500
17.92 MPa
(2600 psi)
N30ZDRS, N35ZRS, and N40ZRS
Hydraulic System Motor
Pump
Displacement
Speed
(RPM)
Max Pump
Pressure
24V 19.20cc 105 to 3300
20.68 MPa
(3000 psi)
Main Lift Pump and Motor
36V 19.20cc 105 to 3300
20.68 MPa
(3000 psi)
Relief Valves
Model Valve Function Relief Pressure1
Main Lift Relief Valve Pressure 20.99 MPa (3045 psi)
N30ZDR, N35ZDR, N35ZR,
N40ZR, N45ZR Auxiliary Relief Valve Pressure 17.92 MPa (2600 psi)
N30ZDRS, N35ZRS, N40ZRS Main Lift Relief Valve Pressure 17.24 MPa (2500 psi)
1
All measurements made when hydraulic oil temperature is 38 to 66 C (100 to 150 F).
2

4. 8000 SRM 1198 Lift Specifications
Lift Specifications
N30ZDR, N35ZDR, N35ZR, N40ZR, and N45ZR
Amp Draw Pressure (psi)
Model Voltage Load
Lift
Speed1
(Ft/
Min)
Free
Lift
Main
Lift
Free
Lift
Main
Lift
Lower
Speed2
(Ft/
Min)
0 100 245 365
4.48 MPa
(650 psi)
5.86 MPa
(850 psi)
98
907 kg
(2000 lb)
- - - - -
1134 kg
(2500 lb)
- - - - -
1361 kg
(3000 lb)
- - - - -
N35ZR
Lift Capacity
1588 kg
(3500 lb)
36
1588 kg
(3500 lb)
60 320 380
10.48 MPa
(1520 psi)
13.20 MPa
(1915 psi)
103
0 100 245 365
4.48 MPa
(650 psi)
5.86 MPa
(850 psi)
98
907 kg
(2000 lb)
- - - - - -
1361 kg
(3000 lb)
70 - - - - -
1588 kg
(3500 lb)
- - - - - -
N40ZR
Standard
Lift Capacity
1814 kg
(4000 lb)
36
1814 kg
(4000 lb)
60 320 380
11.41 MPa
(1655 psi)
14.48 MPa
(2100 psi)
103
0 115 375 480
5.52 MPa
(800 psi)
8.62 MPa
(1250 psi)
100
907 kg
(2000 lb)
- - - - - -
1134 kg
(3000 lb)
80 - - - - -
1588 kg
(3500 lb)
- - - - - -
N40ZR
High
Performance
Option
Lift Capacity
1814 kg
(4000 lb)
36
1814 kg
(4000 lb)
65 480 530
11.38 MPa
(1650 psi)
16.20 MPa
(2350 psi)
105
1
Lift Speed Tolerance +3% and 10%
2
Lower Speed Tolerance +5% and 10%
3

5. Lift Specifications 8000 SRM 1198
N30ZDR, N35ZDR, N35ZR, N40ZR, and N45ZR
Amp Draw Pressure (psi)
Model Voltage Load
Lift
Speed1
(Ft/
Min)
Free
Lift
Main
Lift
Free
Lift
Main
Lift
Lower
Speed2
(Ft/
Min)
0 100 245 365
4.48 MPa
(650 psi)
5.86 MPa
(850 psi)
98
907 kg
(2000 lb)
- - - - - -
1134 kg
(2500 lb)
- - - - - -
N30ZDR
Standard
Lift Capacity
1361 kg
(3000 lb)
36
1361 kg
(3000 lb)
70 320 380
10.48 MPa
(1520 psi)
13.20 MPa
(1915 psi)
103
0 115 375 480
5.52 MPa
(800 psi)
8.62 MPa
(1250 psi)
100
907 kg
(2000 lb)
- - - - - -
1134 kg
(2500 lb)
- - - - - -
N30ZDR
High
Performance
Option
Lift Capacity
1361 kg
(3000 lb)
36
1361 kg
(3000 lb)
80 480 530
11.03 MPa
(1600 psi)
15.86 MPa
(2300 psi)
105
0 115 300 440
5.52 MPa
(800 psi)
8.62 MPa
(1250 psi)
105
907 kg
(2000 lb)
- - - - - -
1361 kg
(3000 lb)
80 - - - - -
1588 kg
(3500 lb)
75 - - - - -
1814 kg
(4000 lb)
70 - - - - -
N45ZR
Standard
Lift Capacity
2041 kg
(4500 lb)
36
2041 kg
(4500 lb)
65 500 540
11.38 MPa
(1650 psi)
16.55 MPa
(2400 psi)
105
1
Lift Speed Tolerance +3% and 10%
2
Lower Speed Tolerance +5% and 10%
4

6. 8000 SRM 1198 Lift Specifications
N30ZDR, N35ZDR, N35ZR, N40ZR, and N45ZR
Amp Draw Pressure (psi)
Model Voltage Load
Lift
Speed1
(Ft/
Min)
Free
Lift
Main
Lift
Free
Lift
Main
Lift
Lower
Speed2
(Ft/
Min)
0 130 375 482
5.45 MPa
(790 psi)
8.89 MPa
(1290 psi)
105
907 kg
(2000 lb)
- - - - - -
1361 kg
(3000 lb)
90 - - - - -
1588 kg
(3500 lb)
- - - - - -
1814 kg
(4000 lb)
80 560 690
13.67 MPa
(1982 psi)
18.44 MPa
(2675 psi)
-
N45ZR
High
Performance
Option
Lift Capacity
2041 kg
(4500 lb)
36
2041 kg
(4500 lb)
75 - -
14.48 MPa
(2100 psi)
19.65 MPa
(2850 psi)
105
0 115 307 440
4.94 MPa
(717 psi)
8.53 MPa
(1237 psi)
100
907 kg
(2000 lb)
- - - - - -
1134 kg
(2500 lb)
- - - - - -
1361 kg
(3000 lb)
75 - - - - -
N35ZDR
Standard
Lift Capacity
1588 kg
(3500 lb)
36
1588 kg
(3500 lb)
70 500 540
11.27 MPa
(1635 psi)
16.06 MPa
(2330 psi)
105
0 130 - -
5.17 MPa
(750 psi)
8.62 MPa
(1250 psi)
105
907 kg
(2000 lb)
- - - - - -
1134 kg
(2500 lb)
- - - - - -
1361 kg
(3000 lb)
- - - - - -
N35ZDR
High
Performance
Option
Lift Capacity
1588 kg
(3500 lb)
36
1588 kg
(3500 lb)
70 - -
11.38 MPa
(1650 psi)
16.20 MPa
(2350 psi)
105
1
Lift Speed Tolerance +3% and 10%
2
Lower Speed Tolerance +5% and 10%
5

7. Lift Specifications 8000 SRM 1198
N30ZDRS, N35ZRS, and N40ZRS
Amp Draw Pressure (psi)
Model Voltage Load
Lift
Speed1
(Ft/
Min)
Free
Lift
Main
Lift
Free
Lift
Main
Lift
Lower
Speed2
(Ft/
Min)
0 66 323 329
2.76 MPa
(400 psi)
4.14 MPa
(600 psi)
85
1361 kg
(3000 lb)
45 352 367
8.96 MPa
(1300 psi)
11.03 MPa
(1600 psi)
-
N35ZRS
Lift Capacity
1588 kg
(3500 lb)
24
1588 kg
(3500 lb)
37 353 374
9.65 MPa
(1400 psi)
12.41 MPa
(1800 psi)
100
0 66 323 329
2.76 MPa
(400 psi)
4.14 MPa
(600 psi)
85
1361 kg
(3000 lb)
45 352 367
8.96 MPa
(1300 psi)
11.03 MPa
(1600 psi)
-
1588 kg
(3500 lb)
37 353 374
9.65 MPa
(1400 psi)
12.41 MPa
(1800 psi)
100
N40ZRS
Lift Capacity
1814 kg
(4000 lb)
24
1814 kg
(4000 lb)
35 366 382
10.34 MPa
(1500 psi)
13.10 MPa
(1900 psi)
103
0 66 323 329
2.76 MPa
(400 psi)
4.14 MPa
(600 psi)
85
907 kg
(2000 lb)
- - - - - -
1134 kg
(2500 lb)
- - - - - -
N30ZDRS
Lift Capacity
1361 kg
(3000 lb)
24
1134 kg
(3000 lb)
45 352 367
8.96 MPa
(1300 psi)
11.03 MPa
(1600 psi)
100
0 77 216 224
2.76 MPa
(400 psi)
4.14 MPa
(600 psi)
85
907 kg
(2000 lb)
62 305 325
6.89 MPa
(1000 psi)
9.65 MPa
(1400 psi)
-
1361 kg
(3000 lb)
57 318 330
8.96 MPa
(1300 psi)
11.03 MPa
(1600 psi)
-
N35ZRS
Lift Capacity
1588 kg
(3500 lb)
36
1588 kg
(3500 lb)
56 327 344
9.65 MPa
(1400 psi)
12.41 MPa
(1800 psi)
100
1
Lift Speed Tolerance +3% and 10%
2
Lower Speed Tolerance +5% and 10%
6

8. 8000 SRM 1198 Lift Specifications
N30ZDRS, N35ZRS, and N40ZRS
Amp Draw Pressure (psi)
Model Voltage Load
Lift
Speed1
(Ft/
Min)
Free
Lift
Main
Lift
Free
Lift
Main
Lift
Lower
Speed2
(Ft/
Min)
0 77 216 224
2.76 MPa
(400 psi)
4.14 MPa
(600 psi)
85
907 kg
(2000 lb)
62 305 325
6.89 MPa
(1000 psi)
9.65 MPa
(1400 psi)
-
1361 kg
(3000 lb)
57 318 330
8.96 MPa
(1300 psi)
11.03 MPa
(1600 psi)
-
1588 kg
(3500 lb)
56 327 344
9.65 MPa
(1400 psi)
12.41 MPa
(1800 psi)
-
N40ZRS
Lift Capacity
1814 kg
(4000 lb)
36
1814 kg
(4000 lb)
50 341 352
10.34 MPa
(1500 psi)
13.10 MPa
(1900 psi)
103
0 77 216 244
2.76 MPa
(400 psi)
4.14 MPa
(600 psi)
85
907 kg
(2000 lb)
- - - - - -
1134 kg
(2500 lb)
- - - - - -
N30ZDRS
Lift Capacity
1361 kg
(3000 lb)
36
1361 kg
(3000 lb)
57 318 330
8.96 MPa
(1300 psi)
11.03 MPa
(1600 psi)
100
1
Lift Speed Tolerance +3% and 10%
2
Lower Speed Tolerance +5% and 10%
7

9. Torque Specifications 8000 SRM 1198
Tire Sizes
Model Drive (in.) Caster (mm) Load Wheels (in.)
12.5 × 5.5 × 8.0 Rubber 5 × 3
N30ZDR, N35ZR,
N40ZR, N30ZDRS,
N35ZRS, N40ZRS 12.5 × 5.5 × 8.0 Poly
200 × 50
5 × 4
13.5 × 5.5 × 8.0 Rubber 5 × 3
13.5 × 5.5 × 8.0 Poly 5 × 4
N45ZR, N35ZDR
13.5 × 5.5 × 8.0 Siped Poly
200 × 50
6 × 4
Torque Specifications
MASTER DRIVE UNIT
Wheel Nuts
136 N•m (100 lbf ft)
Use cross pattern to snug, half torque, then full
torque. Apply antiseize to threads.
Drive Unit to Frame Capscrews
95 N•m (70 lbf ft)
Use cross pattern to snug, half torque,
then full torque.
Traction Motor to Drive Unit
23 N•m (17 lbf ft)
Use cross pattern to snug, half torque,
then full torque.
REACH CARRIAGE
Center Bearing Retainer Capscrews
Apply Loctite® 242 to capscrews and install
into bearing cap along with belleville washers.
Tighten to snug, then tighten each capscrew
incrementally in a clockwise rotation to maintain
even pressure the bearing. Capscrews are tight
when belleville washers are flat.
Scissor Arm Stud Castle Nuts (Dou-
ble Reach Only)
115 N•m (85 lbf ft)
Slightly loosen castle nut as necessary to
align cotter pin holes.
Reach Cylinder Rod End Capscrews
35 to 40 N•m (26 to 30 lbf ft)
Tilt Cylinder Rod Nut
34 N•m (25 lbf ft)
then back off 2 turns.
Load Backrest
102 N•m (75 lbf ft)
MAST
Overhead Guard to Mast
149 N•m (110 lbf ft)
Cylinder Bleed Screws
7 ±1 N•m (62 ±9 lbf in)
Lower Mast Mounting Capscrews
203 N•m (150 lbf ft)
Mast Trunnion Capscrews
210 N•m (155 lbf ft)
8

10. 8000 SRM 1198 Fuses
HYDRAULIC SYSTEM (N30-35ZDR AND
N35-40-45ZR)
Hydraulic Filter Cover
6 N•m (53 lbf in)
Hydraulic Filter Housing to Tank
8 N•m (72 lbf in)
Breather Assembly to Tank
1.5 N•m (18.0 lbf in)
Pump Pressure Flange
40 N•m (30 lbf ft)
Tighten to touch, then 1/8th turn alternately
until full torque.
Lift Pump to Motor Mounting Capscrews
47 N•m (35 lbf ft)
Tighten to touch, then 1/8th turn alternately
until full torque.
HYDRAULIC SYSTEM (N30ZDRS AND
N35-40ZRS)
Hydraulic Filter Cover
6 N•m (53 lbf in)
Hydraulic Filter Housing to Tank
8 N•m (72 lbf in)
Breather Assembly to Tank
1.5 N•m (18.0 lbf in)
Tank Plug (Top)
20 N•m (15 lbf ft)
Tank Plug (Bottom)
67 N•m (50 lbf ft)
Tank Plug (Top)
8 N•m (72 lbf in)
Pump Fittings
80 N•m (59 lbf ft)
Tighten to touch, then 1/8th turn alternately
until full torque.
Lift Pump to Motor Mounting Capscrews
61 N•m (45 lbf ft)
Tighten to touch, then 1/8th turn alternately
until full torque.
STEERING SYSTEM
Steer Motor Mounting Capscrews
23 N•m (17 lbf ft)
LOAD WHEELS
Load Wheel Axle Bolt
68 N•m (50 lbf ft)
Apply antiseize to axles on nongreaseable
load wheel assemblies.
Fuses
Fuse Circuit Rating
FU 10 Key Switch Input 10 Amp
FU 11 24-Volt Supply 10 Amp
FU 12 12-Volt Supply 10 Amp
FU 13 Input to Controllers 10 Amp
FU 14 Spare 10 Amp
FU JP2 Voltage Regulator 7.5 Amp
9

11. Coil Resistance Values 8000 SRM 1198
Coil Resistance Values
Coil Location Resistance Test Points
Main Contactor Control Compartment 32.0 ±4.0 ohms Coil Leads
Load Hold Hydraulic Pump 40.0 ±5.0 ohms Coil Leads
Tilt Selector Attachment 40.0 ±5.0 ohms Coil Leads
Sideshift Attachment 40.0 ±5.0 ohms Coil Leads
Auxiliary Straight Attachment 40.0 ±5.0 ohms Coil Leads
Auxiliary Reverse Attachment 40.0 ±5.0 ohms Coil Leads
Extend/Retract Attachment 40.0 ±5.0 ohms Coil Leads
Brake Traction Motor 11.9 ±1.0 ohms Coil Leads
Electrical Cooling Fan(s)
Under Front Panel (LH)
Drive Unit Door (Optional)
2.2 ±0.5 milliohms Connector Pins
Traction Motor Windings
Winding to Line Resistance (milliohm)
Voltage
Min Max
24 3.22 3.83
36 3.22 3.83
Hydraulic Motor Windings
Winding to Line Resistance (milliohm)
Pump Displacement Voltage
Min Max
19.2cc 24 to 36 2.27 2.70
25.0cc 36 2.55 3.03
25.0cc 36 2.27 2.70
28.0cc 36 1.19 1.37
20.0cc 36 (EE) 2.27 2.70
10

12. 8000 SRM 1198 Battery Specifications
Battery Specifications
Battery Compartment
Minimum Clearance1
Maximum Battery
Dimensions1
Model
Length Width Length Width
986.0 mm
(38.8 in.)
318.0 mm
(12.5 in.)
986.0 mm
(38.8 in.)
311.0 mm
(12.3 in.)
986.0 mm
(38.8 in.)
371.0 mm
(14.6 in.)
986.0 mm
(38.8 in.)
365 mm
(14.4 in.)
N30ZDRS, N35ZRS,
N40ZRS
24V
986.0 mm
(38.8 in.)
422.0 mm
(16.6 in.)
986.0 mm
(38.8 in.)
416.0 mm
(16.4 in.)
986.0 mm
(38.8 in.)
371.0 mm
(14.6 in.)
986.0 mm
(38.8 in.)
365.0 mm
(14.4 in.)
N30ZDR, N35ZR, N40ZR,
N30ZDRS, N35ZRS,
N40ZRS
36V
986.0 mm
(38.8 in.)
422.0 mm
(16.6 in.)
986.0 mm
(38.8 in.)
416.0 mm
(16.4 in.)
986.0 mm
(38.8 in.)
422.0 mm
(16.6 in.)
986.0 mm
(38.8 in.)
416.0 mm
(16.4 in.)
986.0 mm
(38.8 in.)
478.0 mm
(18.8 in.)
986.0 mm
(38.8 in.)
473.0 mm
(18.6 in.)
N45ZR, N35ZDR 36V
986.0 mm
(38.8 in.)
536.0 mm
(21.1 in.)
986.0 mm
(38.8 in.)
530.0 mm
(20.9 in.)
Battery Maximum Height (All Models) 787.0 mm (31.0 in.)
1
Battery measurements refer to length as the dimension between battery retainer plates on either side of
the lift truck. Width refers to the most narrow dimension of the battery.
Battery Weight
Model
Min Max
635 kg (1400 lb) 862 kg (1900 lb)
703 kg (1550 lb) 953 kg (2100 lb)
N30ZDRS, N35ZRS, N40ZRS 24V
771 kg (1700 lb) 1032 kg (2275 lb)
703 kg (1550 lb) 953 kg (2100 lb)
N30ZDR, N35ZR, N40ZR, N30ZDRS,
N35ZRS, N40ZRS
36V
771 kg (1700 lb) 1089 kg (2400 lb)
771 kg (1700 lb) 1089 kg (2400 lb)
998 kg (2200 lb) 1293 kg (2850 lb)
N45ZR, N35ZDR 36V
1134 kg (2500 lb) 1361 kg (3000 lb)
11

13. 1800 SRM 1188 Introduction
Introduction
GENERAL
This section contains the description and replace-
ment procedures for the spring applied, electri-
cally-released parking brake. Some parts associated
with the brake system are not covered in this section
because they are more closely associated with other
systems. See the section Electrical System 2200
SRM 1191 for information on parking brake wiring
and the brake foot switch.
Throughout this section, forward will refer to travel
in the direction of the forks and left and right deter-
mined by an operator standing in the operator com-
partment facing the forks. See Figure 1.
A. LEFT SIDE
B. RIGHT SIDE
C. FORWARD TRAVEL
Figure 1. Truck Orientation
DISCHARGING THE CAPACITORS
When working with the electrical systems of the
truck, it is necessary to discharge the capacitors of
the controllers associated with each circuit affected.
WARNING
DO NOT make repairs or adjustments unless
you have both authorization and training. Re-
pairs and adjustments that are not correct can
create dangerous operating conditions. DO
NOT operate a lift truck that needs repairs.
Report the need for repairs to your supervisor
immediately. If repair is necessary, attach a
DO NOT OPERATE tag on the steering wheel.
Remove the key from the key switch.
Disconnect the battery before opening the elec-
trical compartment covers or inspecting or re-
pairing the electrical system. If a tool causes
a short circuit, the high current flow from the
battery can cause personal injury or property
damage.
Some checks and adjustments are done with
the battery connected. DO NOT connect the
battery until the procedure tells you to do so.
Never have any metal on your fingers, arms,
or neck. Metal items can accidentally make an
electrical connection and cause injury.
Before performing any tests or adjustments,
block the lift truck to prevent unexpected
movement.
The capacitor in the transistor controller(s)
can hold an electrical charge after the battery
is disconnected. To prevent an electrical shock
and personal injury, discharge the capacitor(s)
before inspecting or repairing any component
in the electrical compartments. Wear safety
glasses. Make certain that the battery has
been disconnected.
DO NOT short across the motor controller ter-
minals with a screwdriver or jumper wire.
CAUTION
To avoid controller damage, always disconnect
the battery, discharge the capacitor(s), and
never put power to the controller while any
power wires are disconnected. Never short
any controller terminal or motor terminal to
the battery. Make sure to use proper proce-
dure when servicing the controller.
1. Move the lift truck to a safe, level area and com-
pletely lower the mast. Turn the key switch to
the OFF position and attach a DO NOT OPER-
ATE tag to the control handle. Block the drive
wheel to prevent unexpected movement.
1

14. Electric Brake 1800 SRM 1188
2. Disconnect the battery power cable connector
from the truck connector located on the right side
of the frame. Pull the battery cable connector
handle to separate the battery connector from
the truck connector.
3. Remove the operator compartment cover.
4. Discharge the capacitor in the controllers by
connecting a 200-ohm, 2-watt resistor across the
controller B+ and B terminals of the motor
controller. Remove the resistor after discharging
the capacitors. See Figure 2.
1. POSITIVE CONNECTION (B+)
2. NEGATIVE CONNECTION (B )
3. INSULATED JUMPER WIRES
4. 200-OHM, 2-WATT RESISTOR
Figure 2. Discharging the Capacitors
Electric Brake
The electric brake is located in the drive unit com-
partment mounted to the top of the traction motor.
It consists of a spring-applied, electrically-released
brake mounted directly to the drive motor. See
Figure 3. The electric brake is controlled by the
master controller. After receiving input signals from
the floor switches and a traction input from the
multifunction control handle, the master controller
will complete the circuit to the brake coil, releasing
the brake. The master controller breaks the power
supply to the brake coil, engaging the electric brake
when the truck is stopped. Pressing the emergency
disconnect will apply the electric brake immediately
in any mode of operation. The electric brake may
be manually released for towing by inserting two
standard 1/4-20 × 1-1/4 in. capscrews into the two
threaded holes in the top of the brake assembly. See
Figure 4.
1. FRAME
2. MAST TRUNNIONS
3. BATTERY COMPARTMENT
4. FLOOR MAT
5. TRACTION MOTOR
6. BRAKE ASSEMBLY
Figure 3. Brake Location
2

15. 1800 SRM 1188 Electric Brake
1. SERVICE CAPSCREWS
2. SERVICE PORTS
3. BRAKE ASSEMBLY
4. ASSEMBLY HOLES
Figure 4. Manual Release
AIR GAP
CAUTION
The brake is not adjustable. Check the air gap
to determine if replacement is necessary.
NOTE: The air gap is very thin and may not be
checked visually. Dimensions are not to scale and
are for location references only.
1. Check the three outer socket head screws for ap-
propriate torque to secure the brake to the motor.
2. Check for correct air gap by measuring the
distance between the bottom of the stator and
the top of the pressure plate with the brake
applied (disconnected) using feeler gauges. Air
gap should measure 0.20 to 0.40 mm (0.008 to
0.015 in.). See Figure 5.
3. The air gap should be checked for minimum and
maximum clearance at the six locations shown in
Figure 6.
4. If the air gap allows the maximum feeler gauge to
enter any of the six locations, replace the entire
brake assembly. See Remove.
5. If the air gap is too tight for a minimum feeler
gauge to enter any of the six locations, the air
gap has been altered by internal damage or tam-
pering. Replace the entire brake assembly. See
Remove.
NOTE: During brake operation, the brake should en-
gage and release with a solid, single-click noise. A
double-clicking noise indicates that one side of the
brake is releasing before the other.
6. Listen to verify the brake releases and applies
in one smooth operation. A double-clicking noise
indicates that one side of the brake is releasing
before the other due to internal damage or tam-
pering. Replace the entire brake assembly. See
Remove.
1. STATOR
2. AIR GAP
3. PRESSURE PLATE
4. FEELER GAUGE
Figure 5. Air Gap
3

16. Electric Brake 1800 SRM 1188
Figure 6. Check Locations (Typical Brake)
REMOVE
The following procedures detail the removal and in-
stallation procedures for the electric brake.
The brake assembly is nonadjustable and contains no
service parts. If the brake fails to function, it must be
replaced as a complete assembly. Check the electric
brake before each shift for proper operation. Refer to
Periodic Maintenance 8000 SRM 1197.
1. Move the lift truck to a safe, level area and com-
pletely lower the mast. Turn the key switch to
the OFF position and attach a DO NOT OPER-
ATE tag to the control handle. Block the drive
wheel to prevent unexpected movement. See Fig-
ure 7.
2. Disconnect the battery power cable connector
from the truck connector located on the right side
of the frame. Pull the battery cable connector
handle to separate the battery connector from
the truck connector.
3. Open the drive unit compartment door.
4. Disconnect the electric brake wiring harness
from the main wiring harness near the electric
brake assembly.
5. Remove the four capscrews, lockwashers, and
washers securing the brake assembly to the
drive motor.
6. Lift the brake assembly up off the hub and the
motor housing.
1. ELECTRIC BRAKE AND HUB
2. CAPSCREW
3. LOCKWASHER
4. WASHER
5. RETAINING RING
6. WOODRUFF KEY
Figure 7. Electric Brake
7. Remove the retaining ring securing the hub to
the motor shaft.
8. Remove the hub from the motor shaft. Recover
the Woodruff key.
INSTALL
1. Install the Woodruff key to the motor shaft. Align
the groove in the hub with the Woodruff key and
Install the hub onto the motor shaft.
2. Install the retaining ring onto the motor shaft to
secure the hub.
3. Position the brake assembly onto the hub. Align
the brake mounting slots with the mounting
holes in the motor housing (as removed) and
secure using four capscrews, lockwashers, and
washers. See Figure 7.
4. Install brake wiring harness to the main wiring
harness as removed.
5. Connect the battery. Turn key switch to the ON
position and listen for the electric brake to re-
lease. Check for proper operation.
6. Secure the drive unit compartment door closed.
Remove the DO NOT OPERATE tag from the
control handle and remove the blocks from drive
wheel.
4

17. 1800 SRM 1188 Troubleshooting
Troubleshooting
PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION
Electric brake will not re-
lease.
Key switch is in the OFF position. Turn key switch to the ON position.
Battery is not connected or is dis-
charged.
Connect or clean battery connections.
Charge if necessary.
Wiring or controller malfunction(s). Refer to wiring diagrams.
Excessive wear. Replace the brake assembly.
Brake coil is defective. Check brake coil resistance. Resis-
tance should read 11.9 ohms ±1.0
ohm. Replace brake assembly if nec-
essary.
Foot switches not engaged or not
working properly.
Check battery voltage at brake coil
connector.
Multifunction handle not in FWD or
REV position.
Set multifunction handle to FWD or
REV position.
Electric brake will not apply. Internal mechanical damage to
brake.
Replace the brake assembly.
Electric brake does not hold
truck loaded to specification.
Oil or grease on the friction surfaces. Replace the brake assembly.
Friction surfaces are worn out. Replace the brake assembly.
Springs are too weak. Replace the brake assembly.
Load exceeds truck capacity. Handle only approved load weight.
Brake components worn or damaged. Replace the brake assembly.
Brake coil defective. Replace the brake assembly.
5

18. Troubleshooting 1800 SRM 1188
PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION
Brake drags or gets hot. Battery is discharged or connections
are loose or dirty.
Clean battery connections. Charge if
necessary.
Excessive wear. Replace brake assembly.
Brake coil defective. Check coil resistance. Resistance
should read 11.9 ohms ±1.0 ohm.
Oil or grease in brake. Replace brake assembly.
Incorrect brake air gap. Check air gap is within 0.007 to 0.015
inch. Replace brake assembly if gap
is not within specification.
6

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20. 100 SRM 1185 Repairs - General
General
WARNING
DO NOT make repairs or adjustments unless
you have been properly trained and specifi-
cally authorized to do so. Repairs and adjust-
ments that are incorrect can create dangerous
operating conditions.
DO NOT operate a lift truck that needs repairs.
Report the need for repairs to your supervisor
immediately. If repair is necessary, disconnect
the battery and attach a DO NOT OPERATE tag
to the control handle.
This section contains descriptions of the frame com-
ponents, repair procedures, and assembly informa-
tion. These components include the frame weldment,
door, floor plate, and covers. The overhead guard and
base arms are also covered in this section.
Throughout this section, forward will refer to travel
in the direction of the forks, and left and right will be
from the perspective of an operator in the operator
compartment facing the forks. See Figure 1.
A. LEFT
B. RIGHT
C. FORWARD
Figure 1. Travel Orientation
Description
The frame is available in two sizes: small chassis
and large chassis. The small chassis is used for the
N30ZDR, N35-40ZR, N30ZDRS, and N35-40ZRS
unit and uses a smaller drive unit. The small chas-
sis frame is available with a 368.3 mm (14.5 in.) or
419.1 mm (16.5 in.) battery compartment width.
The large chassis is used for the N35ZDR and N45ZR
unit and uses a larger drive unit. The large chas-
sis frame is available with a 419.1 mm (16.5 in.),
469.9 mm (18.5 in.), or 546.1 mm (21.5 in.) battery
compartment width.
The frame has mounts for the following parts:
• Mast Assembly
• Steering System Parts
• Electrical System Parts
• Hydraulic System Parts
• Door, Floor Plate, Access Panels, and Covers
The overhead guard fastens to the mast. A rear op-
erator guard leg provides protection for the operator
and unobstructed operation of the lift truck. The op-
erator guard leg fastens between the overhead guard
and the frame. Repair procedures for major compo-
nents that fasten to the frame are in separate sec-
tions. See each section for the system that has the
part to be repaired.
Repairs - General
Repair is seldom required on the frame unless the
truck has been structurally damaged. Most truck re-
pairs involve removing the system parts that attach
to the frame. Refer to the appropriate section for the
system that needs repair. To separate the mast from
the frame, refer to the sections Mast, Repair 4000
SRM 1195 and Reach Carriages 4500 SRM 1196.
To replace the load wheels in the base arms, see the
section Periodic Maintenance 8000 SRM 1197 or
Load Wheels in this section.
The caster wheel assembly is part of the steering
assembly. See the section Steering System 1600
SRM 1187 to replace the caster wheel assembly or
the caster wheels.
To replace the drive wheels or tires, see the section
Periodic Maintenance 8000 SRM 1197.
1

21. Covers, Panels, and Plates 100 SRM 1185
WELDING
WARNING
Remove the battery and disconnect the battery
connector before welding. Welding can cause a
fire and/or an explosion. Make sure there is no
oil or grease near the weld area and that the
area is well-ventilated.
Forklift truck frames and components may
have polyurethane paint. Welding, burning, or
other heat sufficient to cause thermal decom-
position of the paint may release isocyanates.
These chemicals are allergic sensitizers to the
skin and respiratory tract irritants. Overexpo-
sure may occur without odor warning. When
performing work, utilize good industrial hy-
giene practices, including removal of all paint
(prime and finish coats) to the metal around
the area to be welded. Use local ventilation,
and/or supplied, air-respiratory protection.
CAUTION
Certain welding repairs require factory ap-
proval. Structural members such as base
arms, axle weldments, and mast components
require written Hyster engineering approval
before repairing or replacing. Contact your
local dealer for factory assistance.
CAUTION
Connect the welding ground clamp as close to
the weld area as possible to prevent welding
current from straying.
Only properly trained, authorized technicians should
perform welding repairs.
Covers, Panels, and Plates
FRONT FRAME PANEL (LEFT AND RIGHT)
Remove the screws from the upper and lower ends of
the front frame panel. Pull the lower end of the panel
away from the frame of the lift truck and gently work
up the side of the panel to pull it from the retainer
clips securing the panel to the frame. Pull the top end
tabs out of the operator compartment cover. Repeat
for opposite side as necessary. See Figure 2.
NOTE: On right-side, front frame panels, ensure the
diagnostic connector cap is positioned correctly to al-
low the cover to seat properly.
To install the panel, position the upper end of the
panel partially into the retaining clip on the frame.
Insert the tabs on the upper end of the panel into
the slots in the operator compartment cover. Work
the sides of the panel into the retaining clips until all
areas of the panel are aligned with the frame. Align
the holes in the panel with the mounting brackets
on the frame and loosely install the screws into the
upper end and lower end of the panel. Make certain
the panel is seated correctly against the frame and
tighten the screws to secure in place. See Figure 2.
Figure 2. Front Frame Panel (Left Side)
2

22. 100 SRM 1185 Covers, Panels, and Plates
Legend for Figure 2
1. OPERATOR COMPARTMENT COVER
2. FRAME
3. LOWER BRACKET
4. LOWER SCREW
5. FRONT COVER PANEL (LEFT)
6. TABS
7. UPPER BRACKET
8. UPPER SCREW
OPERATOR COMPARTMENT COVER
Remove the front frame panels from the lift truck.
See Front Frame Panel (Left and Right). Remove
the two screws securing the operator cover to the
frame brackets. One is located on the lower right
side of the operator compartment above the opera-
tor presence switch. The other is located beside the
overhead guard post mount, at the bottom of the cup
holder. Pull the operator compartment cover up from
the front right corner. Continue pulling the cover up
along the edge of the frame in both directions until
the cover is free from the retaining clips. See Fig-
ure 3.
1. OPERATOR COMPARTMENT COVER
2. RETAINING SCREW
3. FRAME
4. FRONT COVER PANEL (LEFT)
Figure 3. Operator Compartment Cover
To install, position the cover over the electrical com-
partment. Align the lip of the cover to the retaining
clips. Press the lip of the cover into the retaining
clips starting at the overhead guard post and con-
tinue around until completely seated. Align the holes
in cover with the mounting brackets and install re-
taining screws as removed. Install the front frame
panels to complete assembly. Refer to Front Frame
Panel (Left and Right).
DRIVE UNIT COMPARTMENT DOOR
Completely loosen the two socket head capscrews se-
curing the drive unit compartment door closed. The
screws are spring-loaded and are retained to the door
by clips. Pull the door open on its hinges. To close,
push the door closed and start both socket head cap-
screws loosely into the mounting holes. When both
screws are started, verify that the door seats prop-
erly against the frame and tighten the screws.
DOOR PAD
Open compartment door and remove the seven cap-
screws holding the pad to the door. Lift the pad over
the steering mechanism and remove.
To instal the pad, lower it over the steering mecha-
nism and position it onto the door. Install the seven
socket head capscrews as removed.
OPERATOR BACK PAD
Side-Stance Models
Remove the five socket head capscrews retaining pad
to the adjuster mechanism and remove the pad.
To install, position the back pad onto the adjuster
mechanism and loosely install the five socket head
capscrews as removed. Verify that the back pad seats
properly to the adjuster mechanism and tighten to
secure as removed.
Forward-Stance Models
NOTE: On models with Aft Travel controls, guide
the aft travel control handle wiring harness into/out
of the frame when installing/removing the operator
back pad.
Remove the operator compartment cover to access
the screw securing the front of the operator back pad
to the frame. Remove the two screws securing the
operator back pad to the frame and remove the pad
from the frame.
3

23. Load Wheels 100 SRM 1185
To install, position the back pad against the frame
as removed. Install the two screws securing pad to
frame as removed, and reinstall the operator com-
partment cover.
OPERATOR FRONT PAD
Remove the operator compartment cover from the lift
truck. See Operator Compartment Cover. Remove
the screws securing the pad brackets to the frame.
Pull the top of the pad away from the frame and then
lift the pad from the lower retaining clips.
To install, position the lower pad brackets into the
retaining clips. Position the upper end of the pad to
the frame. Align the pad bracket holes and install the
screws to secure the pad in place. Install the operator
compartment cover in place.
CASTER WHEEL COVER
Remove the two socket head capscrews on top of the
caster wheel cover and lift cover from the clips secur-
ing it to the frame.
To replace, fit the bottom of the cover into the clips
inside the opening and slide the cover into place. In-
stall two socket head capscrews to secure the top of
the cover in place.
Load Wheels
REMOVE
Slightly raise the base arms and support on blocks as
described in the Periodic Maintenance 8000 SRM
1197. Make sure the base arms and load wheels do
not support any weight.
1. Remove the nut, washers, and axle bolt. See Fig-
ure 4.
2. Remove the load wheels from the hanger brack-
ets.
1. AXLE BOLT
2. WASHER
3. HANGER
BRACKETS
4. AXLE SLEEVE
5. BEARING
6. LOAD WHEEL
7. NUT
Figure 4. Load Wheels
3. Remove the axle sleeves and bearings from the
load wheels. Check for wear or roughness as
the bearings are rotated. Replace both bearings
if wear or roughness is noted. Inspect the load
wheels for damage or wear. Replace as necessary.
CAUTION
Use a hammer and a soft punch when removing
bearings to avoid damage to bearings and/or
load wheel.
4. Remove the hanger bracket from the base arms
and inspect thoroughly. Inspect the base arms
thoroughly for damage.
INSTALL
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. Wear protection
when handling solvents and always follow the
recommendations of the manufacturer.
CAUTION
1. Clean all parts with solvent and inspect thor-
oughly. Replace damaged parts as necessary.
2. Apply lithium grease to the pivot contact on the
hanger brackets. Position the hanger brackets
into the base arms and install the load wheels
and axle sleeves into the hanger brackets. See
Figure 5.
4

24. 100 SRM 1185 Overhead Guard Replacement
1. PIVOT CONTACT
2. HANGER BRACKET
3. LOAD WHEELS
4. BASE ARM
Figure 5. Hanger Bracket Pivots
CAUTION
The bearings are replaced by pressing on the
outer race of the bearing only. Pressing or tap-
ping on the inner race will damage the bearing.
Use a suitable driver when installing bearings
to avoid damage to bearings and/or load wheel.
Replace bearings in sets to maintain proper
wheel loading and operation.
NOTE: Load wheel assemblies that have axle bolts
equipped with lube fittings use side-shielded bear-
ings and must be greased. Assemblies with axle bolts
not equipped with lube fittings use sealed bearings
and cannot be greased.
3. Install the bearings into the load wheels.
a. Sealed Bearings - Install the bearings into
the load wheel assemblies. Position the axle
sleeve into the assembly. Apply antiseize lu-
bricant to the axle bolt.
b. Side-Shielded Bearings - Install one bear-
ing into the load wheel with the shielded side
facing out. Fill the cavity inside of the load
wheel with grease. Install the other bearing
into the load wheel with the shielded side fac-
ing out. Position the axle sleeve into the as-
sembly.
4. Apply grease to the pivot contact on the hanger
brackets. Position the hanger brackets into the
base arms and install the load wheels and axle
sleeves into the hanger brackets.
5. Install a washer onto the axle bolt. Install the
axle bolt through the hanger brackets, bearings,
and axle sleeve with the threads to the inside of
the base arms.
6. Install washers and nuts to the axle bolts. Torque
to 68 N•m (50 lbf ft).
NOTE: If axle shafts are equipped with lube fittings,
grease to fill load wheel cavity. Refer to Periodic
Maintenance 8000 SRM 1197 for regularly sched-
uled maintenance procedures.
Overhead Guard Replacement
WARNING
DO NOT weld mounts for lights or accessories
to the overhead guard. The strength of the
overhead guard can be reduced by welding or
heating.
Install lights and accessories or their mounts
with clamps. The strength of the overhead
guard can be reduced if holes are drilled in the
wrong location or are too large. Contact your
lift truck dealer before welding or drilling
holes in any part of the overhead guard.
The overhead guard assembly is heavy. Be sure
that all lifting devices (hoists, cables, chains,
slings, etc.) are suitable and of adequate capac-
ity to lift the overhead guard.
The overhead guard assembly consists of the over-
head guard and a support post. See Figure 6 and
Figure 7. The overhead guard is attached to the mast
with six capscrews (2) and lockwashers (3). The top
of the support post is bolted to the overhead guard.
The bottom of the post fits into a retainer in the drive
unit compartment.
5

25. Overhead Guard Replacement 100 SRM 1185
Figure 6. Overhead Guard (N35ZDR, N45ZR, N30ZDR, N35-40ZR)
6