service repair manual

1. SERVICE REPAIR
N45ZR N35ZDR [C264]

2. 1600 SRM 1187 General
General
WARNING
The AC Reach Truck has a cooling fan installed
under the front left cover to regulate the mo-
tor controller temperatures. Some trucks have
a motor door fan installed as an added option
for higher temperatures or extreme duty cycle
operations. The cooling fans of the motor con-
trollers and motor compartment (if installed)
run continuously when power is on. Remove
power from the truck by turning the key switch
OFF and unplugging the battery before servic-
ing the truck or removing covers.
If power-on diagnostic checks are necessary re-
quiring servicing the truck with the covers re-
moved or the motor door open, the fans should
be unplugged first or suitable guards installed
over the fans to prevent possible injury from
the rotating blades of the fans. If diagnostic
checks require the lift motor or drive motor to
be used, the motor controller fan is required to
prevent the motor controllers from overheat-
ing and the front left cover for the fan must re-
main in place during operation of the truck.
CAUTION
Electrical components on this truck are po-
larity sensitive and may be damaged if wired
incorrectly. Make sure each electrical wire
connection is tagged and properly identified
before removal or installation. If the proper
location for connection is unclear, consult the
wiring diagram for the truck. Make sure test-
ing meters have adequate voltage and current
capacities to handle the output of the electri-
cal components they are used to check. Never
wire aftermarket components to this truck
without factory approval.
This section describes the disassembly and assembly
of the steering system. There is a description for each
part of the steering system. The steering system is
primarily electronic. The steering handle assembly
turns a steering sensor, which supplies a signal to
the steering controller. The steering controller sends
current to the steering motor, which drives the mas-
ter drive unit (MDU) through a gear set to steer the
lift truck.
WARNING
These lift truck models may be furnished with
automotive or reverse steering. Before work-
ing on any of these lift trucks, be sure of the
type of steering that has been installed on the
lift truck.
Throughout this section, forward will refer to travel
in the direction of the forks. Left and right will be
determined by an operator standing in the operator
compartment facing the forks. See Figure 1.
A. LEFT SIDE
B. RIGHT SIDE
C. FORWARD TRAVEL
Figure 1. Truck Orientation
1

3. General 1600 SRM 1187
DISCHARGING THE CAPACITORS
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. Turn key switch to OFF position and disconnect
the battery. Block load wheels to prevent lift
truck from moving.
2. Remove two screws securing the electrical com-
partment and pull the compartment door open on
its hinges.
NOTE: Some lift trucks are equipped with a premium
controller, which controls the hydraulic motor as well
as the traction motors.
3. Discharge the capacitor in the controller by con-
necting a 200-ohm, 2-watt resistor across the
controller’s B+ and B terminals for 10 seconds
using insulated jumper wires. 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
2

4. 1600 SRM 1187 General
RAISING THE LIFT TRUCK
WARNING
The lift truck must be put on blocks or an ap-
proved stand for some types of maintenance
and repair. The removal of the following as-
semblies will cause large changes in the center
of gravity: mast and load axle, battery, and the
counterweight. When the lift truck is put on
blocks, put additional blocks under the rear of
the frame before removing the mast so the lift
truck cannot fall backward or to the side.
DO NOT raise any point of the truck more than
50 mm (2 in.) without raising the opposite side
to level the truck. If raising the frame above
150 mm (6 in.), remove the mast first and raise
both ends of the frame in 50 mm (2 in.) incre-
ments.
DO NOT raise the lift truck by attaching an
overhead crane to the overhead guard or ar-
eas of the mast that will be damaged. Some
of these components and other lift points are
not designed to support the weight of the lift
truck. The truck can be damaged or it can fall
on someone causing serious injury. Attach a
chain or sling to a support structure of the lift
truck frame.
Put the lift truck on blocks only if the surface is solid,
even, and level. Make sure that any blocks used to
support the lift truck are solid, one-piece units. Put
blocks in front and back of the tires to prevent move-
ment of the lift truck.
How to Raise the Drive Tire End
Refer to the precautions at the beginning of the Rais-
ing the Lift Truck instructions in this section before
attempting to raise the lift truck.
1. Put blocks on each side (front and back) of the
load wheels to prevent movement of the lift truck.
See Figure 3.
1. DRIVE AND CASTER WHEELS 2. LOAD WHEELS
Figure 3. How to Put Lift Truck on Blocks
3

5. Description 1600 SRM 1187
2. Use a special low-clearance hydraulic jack under
the rear of the frame to raise the drive/steer tire
and caster wheels. Another lift truck can also be
used to raise the lift truck. Make sure that the
jack or other lifting device has a capacity of at
least 2/3 of the total weight of the lift truck as
shown on the nameplate.
3. Raise the lift truck only enough to suspend the
drive/steer tire and the caster wheels. Install
blocks under the rear of the frame to support the
lift truck.
How to Raise the Entire Lift Truck
Refer to the precautions at the beginning of the Rais-
ing the Lift Truck instructions in this section before
attempting to raise the lift truck.
WARNING
The mast MUST BE REMOVED to raise the
frame above 150 mm (6 in.).
1. Remove the mast from the lift truck. Refer to
Mast, Repair 4000 SRM 1195.
2. Turn the key to the OFF position and disconnect
the battery from the lift truck at the battery con-
nector.
WARNING
The battery is heavy. Use appropriate lifting
equipment to avoid personal injury.
3. Remove the battery from the lift truck.
WARNING
The truck must be kept level while raising.
4. Raise the lift truck and position solid one-piece
blocks or an approved lift truck frame stand
under the frame. The truck must be kept level
while raising. Frequently reposition jack stands
or blocks under the frame while raising as a
safety precaution in case of equipment failure.
DO NOT raise any point of the frame 50 mm
(2 in.) more than any other point of the frame.
Description
The steering system is primarily electronic. See Fig-
ure 4. The steering handle assembly is attached to
a sensor unit that senses the direction and speed
of rotation of the steering handle. The sensor unit
sends a signal to the steering controller, which, in
turn, controls electrical power to the steering motor
mounted to the MDU mounting plate. The steering
motor turns a gear on the end of the motor shaft that
meshes with a large gear attached to the MDU. As
the steering motor rotates, the MDU also rotates.
The speed of rotation is directly proportional to how
fast the steering wheel is being rotated. The speed
of rotation is also regulated by the speed of the lift
truck. As the speed of the lift truck increases, the
steering controller will slow the speed of the steering
motor as the steering handle is turned.
The lift truck listed on the front cover of this section
come in several optional configurations. All configu-
rations are covered by this section. These lift trucks
are available with two steering operating positions:
• Sidestance
• Fore/Aft Stance
The steering handle assembly used on these lift
trucks also comes in two optional configurations:
• Fixed
• Adjustable
The fixed steering handle assembly has the steering
handle rotation center fixed and cannot be moved.
The adjustable steering handle assembly has a fea-
ture where the steering handle center of rotation may
be moved to provide more efficient and comfortable
operation. Both steering handle options are avail-
able with either stance configuration. With the fore/
aft stance configuration, the steering handle assem-
bly is mounted in the horizontal position. In the
sidestance configuration, the steering handle assem-
bly is mounted at a slight angle toward the operator.
Two versions of the caster assembly are also avail-
able on these lift trucks. The standard configuration
is a nonsteered caster assembly. An optional steered
caster with a separate caster steering controller is
also available.
During startup, the steering system will perform a
self-test and center the drive wheel. The proximity
sensor located on the MDU plate signals the steering
controller when the drive wheel is in the centered
position. The lift truck will "wiggle" during startup
as the drive tire self-centers. The optional steered
caster assembly also includes a centering proximity
switch and will self-center at truck startup.
4

6. 1600 SRM 1187 Description
1. STEERING HANDLE ASSEMBLY
2. SENSOR UNIT
3. STEERING CONTROLLER
4. STEERING MOTOR
5. PROXIMITY SENSOR
6. CASTER CONTROLLER (OPTIONAL)
Figure 4. Typical Steering System
5

7. Description 1600 SRM 1187
The steering caster wheel assembly comprises the
other part of the steering system. The steering
caster wheel assembly comes in two different config-
urations. See Figure 5 and Figure 6.
The standard configuration is a spring-loaded, non-
steered caster wheel assembly. See Figure 5. The
caster wheel assembly has two polyurethane wheels
that are free to rotate about a pivot shaft as the truck
is driven. The caster is spring loaded to allow the
caster wheel assembly to move up and down with
variations in the floor surface and allow the truck to
maintain four-wheel contact at all times.
Figure 5. Nonsteered Caster Wheel Assembly
The optional configuration is a steered caster assem-
bly. See Figure 6. With this configuration, a mo-
tor is mounted to the caster wheel assembly and ro-
tates the polyurethane caster wheels through a gear
drive. The caster wheel centered position is moni-
tored by an electronic proximity sensor mounted in
the steer caster axle beside the steer caster motor.
The caster steering motor is controlled by a separate
caster steering controller located beneath the opera-
tor compartment. As the steering handle is rotated,
the steering signal is sent to both the MDU steering
controller and the caster steering controller to allow
the caster wheels to turn in the same direction as the
MDU. The movement of the MDU and caster wheels
is coordinated to allow for optimum steering geom-
etry to be obtained during steering maneuvers. As
with configuration one, the caster wheel assembly is
spring loaded to allow the caster assembly to move
up and down with variations in the floor surface and
allow the truck to maintain four-wheel contact at all
times.
Figure 6. Steered Caster Wheel Assembly
6

8. 1600 SRM 1187 Steering Handle Assembly
Steering Handle Assembly
FIXED HANDLE
Description
The steering handle assembly links the lift truck op-
erator to the lift truck steering system. See Fig-
ure 7 and Figure 8. As the operator rotates the steer-
ing handle, the handle rotates a steering sensor in
the steering handle assembly. The steering sensor
senses the direction and speed of the steering han-
dle’s rotation and sends signals to the steering con-
troller to steer the lift truck.
Figure 7. Steering Handle Assembly
(Sidestance)
Remove
1. Turn the key to the OFF position and disconnect
the battery connector.
2. Loosen the compartment door mounting cap-
screws (2) and open the compartment door. See
Figure 9.
3. Disconnect the wiring from the steering handle
assembly at the harness connector. Remove the
clamps securing the steering unit wiring to the
frame.
Figure 8. Steering Handle Assembly (Fore/Aft
Stance)
4. If removing the mounting plate from the lift
truck, loosen the capscrews (1) holding the steer-
ing handle assembly to the compartment door.
Remove the steering handle assembly from the
lift truck. Place the assembly on a clean work
surface.
Disassemble
For the following instruction, refer to Figure 10.
1. Remove the four capscrews (12), lockwashers
(11), and washers (10) securing the steer support
pad to the mounting plate.
2. Remove clamps retaining the steering unit har-
ness (not shown).
3. Pry the cover up from the steering handle and
loosen and remove the nut (2) and washer (3)
from the steering unit shaft.
4. Remove the steering handle from the steer sup-
port pad and recover the Woodruff key from the
steering unit shaft.
7

9. Steering Handle Assembly 1600 SRM 1187
1. CAPSCREWS 2. CAPSCREWS
Figure 9. Door Attaching Parts (Sidestance Shown)
WARNING
Be careful when removing or installing retain-
ing rings. Retaining rings can eject during
removal or installation with enough force to
cause injury. Always use the correct retaining
ring pliers and wear eye and face protection
during removal or installation.
5. Remove the cap from the top of the steering han-
dle knob. Remove the retaining ring from the
steering handle pin and remove the knob. Re-
move the plug from the steer support pad if nec-
essary.
NOTE: The steering unit contains no serviceable
parts. If the steering unit fails, it must be replaced
as a complete unit.
6. Loosen and remove the four capscrews (9) and
washers (8) holding the steering unit to the steer
support pad.
8

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11. 1600 SRM 1187 Steering Handle Assembly
Figure 10. Steering Handle (Fixed)
9

12. Steering Handle Assembly 1600 SRM 1187
Legend for Figure 10
1. COVER
2. NUT
3. WASHER
4. WOODRUFF KEY
5. STEERING HANDLE
6. STEER SUPPORT PAD
7. STEERING UNIT
8. WASHER
9. CAPSCREW
10. WASHER
11. LOCKWASHER
12. CAPSCREW
13. WASHER
14. LOCKWASHER
15. CAPSCREW
16. MOUNTING BRACKET
17. SPACER
18. MOUNTING PLATE
19. PLUG
20. KNOB
21. RETAINING RING
22. CAP
7. Remove the four capscrews (15), lockwashers
(14), and washers (13) securing the mounting
plate to the mounting bracket. Recover the spac-
ers from between.
Assemble
For the following instruction, refer to Figure 10.
1. Position the spacers between the mounting
bracket and the mounting plate as removed.
Align the holes in the mounting plate and the
spacers with the holes in the mounting bracket.
Install the four capscrews (15), lockwashers (14),
and washers (13) to secure.
2. Assemble the steering unit to the steer support
pad with the four capscrews (9) and washers (8).
3. Position the steer support pad to the mounting
plate. Secure in place using the four capscrews
(12), lockwashers (11), and washers (10).
4. Install the Woodruff key into the steering unit
shaft. Align the slot in the steering handle with
the key and install the steering handle onto the
steer support pad.
5. Install the washer (3) and nut (2) to secure the
steering handle. Install the cover onto the steer-
ing handle assembly.
WARNING
Be careful when removing or installing retain-
ing rings. Retaining rings can eject during
removal or installation with enough force to
cause injury. Always use the correct retaining
ring pliers and wear eye and face protection
during removal or installation.
6. Slide the knob onto the steering handle pin and
install the retaining ring. Install the cap into the
knob.
7. Install the plug to the steer support pad if re-
moved.
8. Install clamps to retain the steering unit harness
to the steering handle assembly as removed (not
shown).
Install
1. Install the steering handle assembly to the
compartment door with the capscrews (2) as
removed. See Figure 9.
2. Connect the harness from the steering handle as-
sembly to the connector on the main truck har-
ness. Secure using clamps as removed.
3. Close the compartment door and tighten the cap-
screws (1). See Figure 9.
4. Reconnect the battery and turn the key switch to
the ON position. Test for proper operation.
10

13. 1600 SRM 1187 Steering Handle Assembly
ADJUSTABLE HANDLE
Description
The steering handle assembly links the lift truck op-
erator to the lift truck steering system. See Fig-
ure 11. As the operator rotates the steering handle,
the handle rotates a steering sensor in the steering
handle assembly. The steering sensor senses the di-
rection and speed of the steering handle’s rotation
and sends signals to the steering controller to steer
the lift truck.
Figure 11. Steering Handle Assembly
The steering handle assembly is adjustable. The lift
truck operator can move the steering handle’s center
of rotation away from or toward the operating posi-
tion. To adjust the steering handle assembly, lift the
locking pin and rotate the complete steering handle
assembly clockwise or counterclockwise to one of the
eight adjustment positions.
Remove
For the following instructions, refer to Figure 12.
1. Turn the key to the OFF position and disconnect
the battery connector.
2. Loosen the compartment door mounting cap-
screws (2) and open the compartment door.
3. Disconnect the wiring from the steering handle
assembly at the harness connector.
4. If necessary, loosen the capscrews (1) holding the
steering handle assembly to the drive unit com-
partment door. Remove the steering handle as-
sembly from the lift truck. Place the assembly on
a clean work surface.
Disassemble
For the following instructions, refer to Figure 13.
1. Remove the four capscrews, washers, and spac-
ers holding the steer support pad to the mount-
ing plate (inner race). Remove the steer support
pad.
2. Remove the clamps retaining the steering unit
harness to the steering handle assembly (not
shown).
3. Pry the cover up from the steering handle and re-
move the nut and washer from the steering unit
shaft.
4. Remove the steering handle from the steer sup-
port pad and recover the Woodruff key from the
steering unit shaft.
WARNING
Be careful when removing or installing retain-
ing rings. Retaining rings can eject during
removal or installation with enough force to
cause injury. Always use the correct retaining
ring pliers and wear eye and face protection
during removal or installation.
5. Remove the cap from the top of the handle knob.
Remove the retaining ring and remove the han-
dle knob from the steering pin.
NOTE: The steering unit contains no serviceable
parts. If the steering unit fails, it must be replaced
as a complete unit.
6. Loosen and remove the four capscrews (8) and
washers (7) securing the steering unit to the steer
support pad. Separate the steering unit from the
steer support pad.
11

14. Steering Handle Assembly 1600 SRM 1187
1. CAPSCREWS 2. CAPSCREWS
Figure 12. Compartment Door Attaching Parts
12

15. 1600 SRM 1187 Steering Handle Assembly
Figure 13. Steering Handle (Adjustable)
13

16. Steering Handle Assembly 1600 SRM 1187
Legend for Figure 13
1. COVER
2. NUT
3. WASHER
4. WOODRUFF KEY
5. STEERING HANDLE
6. STEERING UNIT
7. WASHER
8. CAPSCREW
9. OUTER RACE (TOP)
10. MOUNTING PLATE (INNER RACE)
11. OUTER RACE (BOTTOM)
12. TILLER LATCH PLATE
13. MOUNTING BRACKET
14. NUT
15. SPACER
16. LOCKWASHER
17. CAPSCREW
18. WASHER
19. LOCKWASHER
20. CAPSCREW
21. CAPSCREW
22. LOCKWASHER
23. WASHER
24. WASHER
25. LOCKWASHER
26. CAPSCREW
27. RETAINING RING
28. BUSHING
29. LOCKING PIN ASSEMBLY
30. STEER SUPPORT PAD
31. PULL KNOB
32. HANDLE KNOB AND CAP
33. RETAINING RING
WARNING
Be careful when removing or installing retain-
ing rings. Retaining rings can eject during
removal or installation with enough force to
cause injury. Always use the correct retaining
ring pliers and wear eye and face protection
during removal or installation.
7. Remove the locking pin assembly from the steer
support pad:
a. Unscrew the pull knob from the shaft.
b. Remove the upper retaining ring and pull the
locking plunger assembly from the steer sup-
port pad.
c. Remove the lower retaining ring and slide
the bushing from the bottom of the steer sup-
port pad.
d. Remove the clip from the lower locking rod
and remove the bushings and the spring
as necessary for repair. Reassemble as re-
moved. See Figure 14.
8. Remove the three capscrews (20), lockwashers
(19), and washers (18) securing the race assem-
bly to the mounting bracket.
9. Remove the four capscrews (26), lockwashers
(25), washers (24) and nuts (14) securing the
outer race (top), mounting plate (inner race),
and outer race (bottom) to the tiller latch plate.
Unstack the races from the tiller latch plate to
complete disassembly.
1. CLIP
2. LOCKING ROD
3. BUSHING
4. SPRING
5. BUSHING
Figure 14. Locking Pin Assembly
14