This document is a Service Repair Manual for Hyster Reach Carriages, specifically covering models N35ZDR, N45ZR [C264]; N35ZDR2, N45ZR2 [D264]; N30ZDR, N35-40ZR [D470]; N35-40ZR2, N30ZDR2 [E470]; N30ZDRS, N35-40ZRS [A265]; and N35-40ZRS2, N30ZDRS2 [B265]. The manual provides detailed instructions for the maintenance and repair of these forklift components.
Function Description
The Hyster Reach Carriages are integral components of reach forklifts, designed to extend the forks forward, allowing the forklift to reach deeper into racking systems. There are two primary types of reach carriages covered: single-reach carriages and double-reach carriages.
- Single-Reach Carriages: These feature one set of scissor arms, enabling a single extension of the forks.
- Double-Reach Carriages: These are equipped with two sets of scissor arms, allowing for a greater extension to reach two pallets deep into a rack.
Both types of carriages incorporate a tilt cylinder for tilting the forks, which is crucial for proper load handling and stability. Additionally, each carriage type is available with an optional sideshift function, providing lateral movement of the forks for precise load positioning without repositioning the entire forklift.
The core mechanism involves a scissor linkage that connects the rear and front frame assemblies. The top of the scissor arm weldment is pinned to the top of the rear frame assembly, and the top of each scissor arm at the front frame is similarly pinned to the top of the front frame assembly. In double-reach units, the ends of each set of scissor arms are connected by studs with bushings, facilitating pivot action. Large bearings at the central pivot points of the scissor arm assemblies also enable the linkage to pivot smoothly.
Important Technical Specifications
While specific numerical specifications like dimensions or weights are not explicitly listed in the provided excerpts, the manual implies several key technical characteristics through its repair procedures:
- Load Backrest Torque: Capscrews for the load backrest must be torqued to 102 N•m (75 lbf ft).
- Safety Chain Size: A minimum safety chain size of 9.5 mm (3/8 in.) is required for securing mast weldments during maintenance.
- Hydraulic System: The carriages rely on a hydraulic system for their reach, tilt, and sideshift functions. References are made to hydraulic lines, fittings, and selector valves (front and rear).
- Roller Bearings: The system utilizes load rollers and thrust roller bearings, which are sealed and permanently lubricated. These components are critical for smooth movement and require inspection for wear, cracks, or restricted turning.
- Position Sensor: Models N35ZDR, N45ZR, N30ZDR, and N35-40ZR are equipped with a position sensor mounted to the right side inner scissor arm pivot pin at the rear frame, indicating the reach position.
- Lift Chains: The carriages incorporate lift chains, which are subject to wear and require regular inspection, cleaning, and lubrication.
- Mast Compatibility: The reach assembly can be removed from the mast with the load backrest and forks attached. Three-stage mast assemblies can also be removed with the reach assembly installed, indicating modularity.
Usage Features
The reach carriages are designed for efficient and precise material handling in warehouse environments, particularly for high-density storage.
- Reach Functionality: Allows operators to extend the forks to pick up or place loads at varying depths within racking.
- Tilt Functionality: The tilt cylinder enables tilting of the forks, which is essential for stabilizing loads during transport and for proper engagement/disengagement with pallets.
- Sideshift Functionality (Optional): Provides lateral adjustment of the forks, reducing the need for the forklift to maneuver extensively for precise load placement, thereby improving efficiency and reducing potential damage to goods or racks.
- Operator Guard: The presence of an operator guard (which must be removed for certain maintenance tasks) highlights a focus on operator safety during operation.
Maintenance Features
The manual emphasizes several key aspects of maintenance to ensure the longevity and safe operation of the reach carriages:
- Regular Inspections: Frequent inspection of rollers (load and side), welds, stub shafts, chain anchor mounts, and lift chains for wear, damage, or cracks is crucial.
- Lubrication: Proper lubrication is highlighted for bushings, thrust washers, shims, stub shafts, and pins of the scissor arm assembly using multipurpose grease. Sealed bearings, however, are permanently lubricated and should not be immersed in solvent or cleaned with steam/compressed air.
- Component Replacement: Instructions are provided for replacing worn or damaged components such as rollers, bushings, and wear strips.
- Hydraulic System Maintenance: Procedures include disconnecting/reconnecting hydraulic lines, capping/plugging open ports to prevent contamination, removing air from the system, and checking/adding hydraulic oil.
- Chain Maintenance: Lift chains require cleaning and lubrication, and their proper adjustment is critical for carriage height and alignment.
- Safety Procedures: The manual extensively details safety precautions, including:
- DISCONNECTING BATTERY CONNECTOR: Essential before any electrical or hydraulic maintenance on electric lift trucks.
- BLOCKING THE UNIT: Using correct blocks to prevent rolling or falling.
- LIFTING DEVICES: Always using appropriate lifting mechanisms for heavy parts and ensuring their adequate capacity.
- SAFETY CHAINS: Installing safety chains when the mast must be in a raised position for repairs, especially around crossmembers of inner and outer weldments.
- PINCH POINTS: Warning against placing hands near pinch points in the scissor arm assembly.
- HYDRAULIC OIL TEMPERATURE: Warning about hot hydraulic oil causing burns.
- SNAP RING HANDLING: Caution regarding the force with which snap rings can eject during removal/installation, requiring proper tools and eye/face protection.
- WELDING REPAIRS: Requiring factory approval from Hyster® to ensure structural integrity and safety.
- CLEANING SOLVENTS: Warnings about flammability, toxicity, and skin irritation, requiring proper protective equipment.
- Adjustments: Procedures for adjusting side rollers, load rollers, reach cylinders, and lift chains are included to ensure optimal performance and alignment.
- Troubleshooting: A dedicated section for troubleshooting is indicated, suggesting guidance for diagnosing and resolving common issues.
- Modular Repair: The design allows for most repairs to be done without completely disassembling the reach carriage or removing it from the mast, provided the scissor arms are fully extended. The front frame can also be serviced without removing the entire reach carriage assembly from the mast.
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