FRAME

N35ZDR, N45ZR [C264];

N30ZDR, N35-40ZR [D470];
N30ZDRS, N35-40ZRS [A265]

PART NO. 1590933 100 SRM 1185

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• 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.
Frame Table of Contents

TABLE OF CONTENTS

General ............................................................................................................................................................... 1
Description ......................................................................................................................................................... 1
Repairs - General ............................................................................................................................................... 2
Covers, Panels, and Plates................................................................................................................................. 2
Front Frame Panel (Left and Right)............................................................................................................. 2
Operator Compartment Cover ...................................................................................................................... 2
Drive Unit Compartment Door ..................................................................................................................... 3
Door Pad ......................................................................................................................................................... 3
Operator Back Pad ........................................................................................................................................ 4
Side-Stance Models ................................................................................................................................... 4
Forward-Stance Models............................................................................................................................. 4
Operator Front Pad ....................................................................................................................................... 4
Caster Wheel Cover ....................................................................................................................................... 4
Load Wheels ....................................................................................................................................................... 4
Remove ........................................................................................................................................................... 4
Install ............................................................................................................................................................. 5
Overhead Guard Replacement .......................................................................................................................... 6
Remove ........................................................................................................................................................... 9
Install ............................................................................................................................................................. 9
Front Lights ................................................................................................................................................... 9
Bulb Replacement ..................................................................................................................................... 9
Assembly Replacement ............................................................................................................................. 10
Rear Work and Caution Light .................................................................................................................. 11
Caution Light ............................................................................................................................................ 11
Painting Instructions ......................................................................................................................................... 12
Safety Labels Replacement ............................................................................................................................... 13

This section is for the following models:

N35ZDR, N45ZR [C264];

N30ZDR, N35-40ZR [D470];
N30ZDRS, N35-40ZRS [A265]

©2011 HYSTER COMPANY i

"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
100 SRM 1185 Description

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, A. LEFT C. FORWARD
B. RIGHT
door, floor plate, and covers. The overhead guard and
base arms are also covered in this section. Figure 1. Travel Orientation
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.

Description
The frame is available in two sizes: small chassis • Electrical System Parts
and large chassis. The small chassis is used for the • Hydraulic System Parts
N30ZDR, N35-40ZR, N30ZDRS, and N35-40ZRS • Door, Floor Plate, Access Panels, and Covers
unit and uses a smaller drive unit. The small chas-
sis frame is available with a 368.3 mm (14.5 in.) or The overhead guard fastens to the mast. A rear op-
419.1 mm (16.5 in.) battery compartment width. erator guard leg provides protection for the operator
The large chassis is used for the N35ZDR and N45ZR and unobstructed operation of the lift truck. The op-
unit and uses a larger drive unit. The large chas- erator guard leg fastens between the overhead guard
sis frame is available with a 419.1 mm (16.5 in.), and the frame. Repair procedures for major compo-
469.9 mm (18.5 in.), or 546.1 mm (21.5 in.) battery nents that fasten to the frame are in separate sec-
compartment width. tions. See each section for the system that has the
part to be repaired.
The frame has mounts for the following parts:
• Mast Assembly
• Steering System Parts

1
Covers, Panels, and Plates 100 SRM 1185

Repairs - General
Repair is seldom required on the frame unless the The caster wheel assembly is part of the steering
truck has been structurally damaged. Most truck re- assembly. See the section Steering System 1600
pairs involve removing the system parts that attach SRM 1187 to replace the caster wheel assembly or
to the frame. Refer to the appropriate section for the the caster wheels.
system that needs repair. To separate the mast from To replace the drive wheels or tires, see the section
the frame, refer to the sections Mast, Repair 4000 Periodic Maintenance 8000 SRM 1197.
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.

Covers, Panels, and Plates

FRONT FRAME PANEL (LEFT AND RIGHT) OPERATOR COMPARTMENT COVER
Remove the screws from the upper and lower ends of Remove the front frame panels from the lift truck.
the front frame panel. Pull the lower end of the panel See Front Frame Panel (Left and Right). Remove
away from the frame of the lift truck and gently work the two screws securing the operator cover to the
up the side of the panel to pull it from the retainer frame brackets. One is located on the lower right
clips securing the panel to the frame. Pull the top end side of the operator compartment above the opera-
tabs out of the operator compartment cover. Repeat tor presence switch. The other is located beside the
for opposite side as necessary. See Figure 2. overhead guard post mount, at the bottom of the cup
holder. Pull the operator compartment cover up from
NOTE: On right-side, front frame panels, ensure the the front right corner. Continue pulling the cover up
diagnostic connector cap is positioned correctly to al- along the edge of the frame in both directions until
low the cover to seat properly. the cover is free from the retaining clips. See Fig-
ure 3. To install, position the cover over the electri-
To install the panel, position the upper end of the
cal compartment. Align the lip of the cover to the
panel partially into the retaining clip on the frame.
retaining clips. Press the lip of the cover into the re-
Insert the tabs on the upper end of the panel into
taining clips starting at the overhead guard post and
the slots in the operator compartment cover. Work
continue around until completely seated. Align the
the sides of the panel into the retaining clips until all
holes in cover with the mounting brackets and install
areas of the panel are aligned with the frame. Align
retaining screws as removed. Install the front frame
the holes in the panel with the mounting brackets
panels to complete assembly. Refer to Front Frame
on the frame and loosely install the screws into the
Panel (Left and Right).
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.

2
100 SRM 1185 Covers, Panels, and Plates

screws are started, verify that the door seats prop-

erly against the frame and tighten the screws.

1. OPERATOR COMPARTMENT COVER

2. FRAME
3. LOWER BRACKET
4. LOWER SCREW 1. OPERATOR COMPARTMENT COVER
5. FRONT COVER PANEL (LEFT) 2. RETAINING SCREW
6. TABS 3. FRAME
7. UPPER BRACKET 4. FRONT COVER PANEL (LEFT)
8. UPPER SCREW
Figure 3. Operator Compartment Cover
Figure 2. Front Frame Panel (Left Side)
DOOR PAD
DRIVE UNIT COMPARTMENT DOOR
Open compartment door and remove the seven cap-
Completely loosen the two socket head capscrews se- screws holding the pad to the door. Lift the pad over
curing the drive unit compartment door closed. The the steering mechanism and remove.
screws are spring-loaded and are retained to the door
by clips. Pull the door open on its hinges. To close, To instal the pad, lower it over the steering mecha-
push the door closed and start both socket head cap- nism and position it onto the door. Install the seven
screws loosely into the mounting holes. When both socket head capscrews as removed.

3
Load Wheels 100 SRM 1185

OPERATOR BACK PAD frame as removed, and reinstall the operator com-
partment cover.
Side-Stance Models
OPERATOR FRONT PAD
Remove the five socket head capscrews retaining pad
to the adjuster mechanism and remove the pad. Remove the operator compartment cover from the lift
truck. See Operator Compartment Cover. Remove
To install, position the back pad onto the adjuster the screws securing the pad brackets to the frame.
mechanism and loosely install the five socket head Pull the top of the pad away from the frame and then
capscrews as removed. Verify that the back pad seats lift the pad from the lower retaining clips.
properly to the adjuster mechanism and tighten to
secure as removed. To install, position the lower pad brackets into the
retaining clips. Position the upper end of the pad to
Forward-Stance Models the frame. Align the pad bracket holes and install the
screws to secure the pad in place. Install the operator
NOTE: On models with Aft Travel controls, guide compartment cover in place.
the aft travel control handle wiring harness into/out
of the frame when installing/removing the operator CASTER WHEEL COVER
back pad.
Remove the two socket head capscrews on top of the
Remove the operator compartment cover to access caster wheel cover and lift cover from the clips secur-
the screw securing the front of the operator back pad ing it to the frame.
to the frame. Remove the two screws securing the
operator back pad to the frame and remove the pad To replace, fit the bottom of the cover into the clips
from the frame. inside the opening and slide the cover into place. In-
stall two socket head capscrews to secure the top of
To install, position the back pad against the frame the cover in place.
as removed. Install the two screws securing pad to

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.

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.
1. AXLE BOLT 4. AXLE SLEEVE
2. WASHER 5. BEARING
3. HANGER 6. LOAD WHEEL
BRACKETS 7. NUT

Figure 4. Load Wheels

4
100 SRM 1185 Load Wheels

CAUTION CAUTION
Use a hammer and a soft punch when removing The bearings are replaced by pressing on the
bearings to avoid damage to bearings and/or outer race of the bearing only. Pressing or tap-
load wheel. ping on the inner race will damage the bearing.
Use a suitable driver when installing bearings
4. Remove the hanger bracket from the base arms to avoid damage to bearings and/or load wheel.
and inspect thoroughly. Inspect the base arms
thoroughly for damage. Replace bearings in sets to maintain proper
wheel loading and operation.
INSTALL
NOTE: Load wheel assemblies that have axle bolts
equipped with lube fittings use side-shielded bear-
WARNING
ings and must be greased. Assemblies with axle bolts
Cleaning solvents can be flammable and toxic not equipped with lube fittings use sealed bearings
and can cause skin irritation. Wear protection and cannot be greased.
when handling solvents and always follow the
recommendations of the manufacturer. 3. Install the bearings into the load wheels.

a. Sealed Bearings - Install the bearings into

CAUTION
the load wheel assemblies. Position the axle
1. Clean all parts with solvent and inspect thor- sleeve into the assembly. Apply antiseize lu-
oughly. Replace damaged parts as necessary. bricant to the axle bolt.

2. Apply lithium grease to the pivot contact on the b. Side-Shielded Bearings - Install one bear-
hanger brackets. Position the hanger brackets ing into the load wheel with the shielded side
into the base arms and install the load wheels facing out. Fill the cavity inside of the load
and axle sleeves into the hanger brackets. See wheel with grease. Install the other bearing
Figure 5. 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).
1. PIVOT CONTACT
2. HANGER BRACKET NOTE: If axle shafts are equipped with lube fittings,
3. LOAD WHEELS grease to fill load wheel cavity. Refer to Periodic
4. BASE ARM
Maintenance 8000 SRM 1197 for regularly sched-
Figure 5. Hanger Bracket Pivots uled maintenance procedures.

5
Overhead Guard Replacement 100 SRM 1185

Overhead Guard Replacement

slings, etc.) are suitable and of adequate capac-
WARNING ity to lift the overhead guard.
DO NOT weld mounts for lights or accessories
to the overhead guard. The strength of the The overhead guard assembly consists of the over-
overhead guard can be reduced by welding or head guard and a support post. See Figure 6 and
heating. Figure 7. The overhead guard is attached to the mast
with six capscrews (2) and lockwashers (3). The top
Install lights and accessories or their mounts of the support post is bolted to the overhead guard.
with clamps. The strength of the overhead The bottom of the post fits into a retainer in the drive
guard can be reduced if holes are drilled in the unit compartment.
wrong location or are too large. Contact your
lift truck dealer before welding or drilling The size of the overhead guard varies depending
holes in any part of the overhead guard. upon the battery compartment size.

The overhead guard assembly is heavy. Be sure

that all lifting devices (hoists, cables, chains,

Legend for Figure 6

1. OVERHEAD GUARD 6. CAPSCREW
2. CAPSCREW 7. PLUG
3. LOCKWASHER 8. SUPPORT POST
4. PLUG (W/O HEAD LAMPS) 9. BUSHING
5. CAPSCREW

6
100 SRM 1185 Overhead Guard Replacement

Figure 6. Overhead Guard (N35ZDR, N45ZR, N30ZDR, N35-40ZR)

7
Overhead Guard Replacement 100 SRM 1185

Figure 7. Overhead Guard (N30ZDRS, N35-40ZRS)

8
100 SRM 1185 Overhead Guard Replacement

Legend for Figure 7

1. OVERHEAD GUARD 5. CAPSCREW
2. CAPSCREW 6. CAPSCREW
3. LOCKWASHER 7. SUPPORT POST
4. PLUG (W/O HEAD LAMPS) 8. BUSHING

REMOVE 2. Remove the bulb from the fixture and replace

with new.
Refer to WARNING (above) before performing ser-
vice to any overhead guard components.
CAUTION
1. Attach a suitable lifting device to the overhead Overtightening the screws can break the lens.
guard.
3. Position the lens and the retainer to the fixture
2. Remove the two capscrews (6) retaining the sup- and install the four screws.
port post to the overhead guard. See Figure 6.
Pull the support post out of the retainer in the
lift truck frame. Remove the support post.

3. Remove the six capscrews (2) and lockwashers (3)

retaining the overhead guard to the mast. Lower
the overhead guard to the floor.

INSTALL
Refer to WARNING (above) before performing ser-
vice to any overhead guard components.

1. Attach a suitable lifting device to the overhead

guard.

2. Align the overhead guard with the top of the mast

and install the six capscrews (2) and lockwash-
ers (3). See Figure 6. Torque the capscrews to
149 N•m (110 lbf ft).

3. Slide the support post into the retainer in the

lift truck frame. Install the two capscrews (6)
retaining the support post to the overhead guard.

FRONT LIGHTS
1. BRACKET
Two front (head) lights are mounted by their brackets 2. RETAINING CAPSCREW AND NUT
to the front of the overhead guard. 3. SCREW
4. LENS RETAINER
5. LENS
Bulb Replacement
Figure 8. Lens Removal
1. Remove the four screws securing the lens re-
tainer and lens to the assembly. Hold the lens
in place until all screws have been removed
then remove the lens and retainer. Replace as
required. See Figure 8.

9
Overhead Guard Replacement 100 SRM 1185

Assembly Replacement 3. Remove the bracket from the overhead guard and
replace, if necessary.
1. Disconnect the wiring harness from the light as-
sembly connector. 4. Install bracket to overhead guard, if removed.

2. Remove the nut and washers from the capscrew 5. Position the light assembly to the bracket and in-
securing the headlight assembly to the bracket. stall capscrew and attaching hardware. Tighten
Slide the capscrew from the bracket and remove slightly to allow for adjustment.
the headlight. See Figure 9.

1. ADJUSTMENT SLOT 5. HEADLIGHT

2. ADJUSTMENT BOLT 6. CONNECTOR
3. OVERHEAD GUARD 7. WIRE CLAMP
4. WIRING HARNESS 8. ATTACHING HARDWARE

Figure 9. Head Light Mounting

10
100 SRM 1185 Overhead Guard Replacement

Rear Work and Caution Light 8. Position the cage onto the studs of the light as-
sembly. Install nuts and washers onto studs.
The rear work and caution lights are options that
mount to the overhead guard near the rear of the 9. Remove blocks from the wheel and return to ser-
truck. Several configurations of these assemblies are vice.
available and connect to the options harness. To re-
pair the light assemblies, perform the following pro-
cedures. Some repairs may not require total disas-
sembly. Perform only the steps necessary to safely
complete the required service. See Figure 10.

The work light is very similar to the front light, ex-

cept for its mounting platform and location. To re-
pair or replace the work light, refer to the instruc-
tions for repairing or replacing the front lights. See
Front Lights.

Caution Light
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.

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 nuts securing the cage to the light

assembly. Remove the cage.
1. CAGE
4. Remove the screws and washers securing the 2. GLOBE
lens globe to the light assembly. Remove the lens 3. STUDS AND NUTS
globe. 4. UPPER MOUNTING FLANGE
5. LOWER MOUNTING FLANGE
5. Remove the bulb from the fixture and replace if 6. SCREW
7. MOUNTING BRACKET
necessary. 8. WORK LIGHT WITH ADJUSTABLE BRACKET
9. WORK LIGHT WIRING HARNESS
6. Connect the battery and turn the key switch to 10. STROBE WIRING HARNESS
the ON position. Test for proper operation.
Figure 10. Rear and Caution Light
7. Position the lens globe to the light assembly. In-
stall screws to secure.

11
Painting Instructions 100 SRM 1185

Painting Instructions
2. Use sandpaper to remove the top surface of
WARNING paint and rust from the metal. All metal sur-
Some frames and components are painted with faces where the paint has been removed to the
polyurethane paint. Welding, burning, or other bare metal must be primed. Apply primer BE-
heat sufficient to cause thermal decomposition FORE applying the paint.
of the paint may release isocyanates. These
chemicals are allergic sensitizers to the skin 3. Protect all surfaces that will not be painted. DO
and respiratory tract irritants. Overexposure NOT paint:
may occur without odor warning. When heat All Plastic Covers
must be applied, use good industrial hygiene Steering Handle
practices, including removal of all paint (prime Dash Display
and finish coats) to the metal around the area Control Handles
to be heated. Use local ventilation, and/or sup- Labels and Information Plates
plied, air-respiratory protection. Operator Pads
Tires and Load Wheels
Cleaning solvents may be flammable and/or Chains and Hoses
toxic and may cause skin irritation. Always Battery Connectors
wear proper eye and skin protection. All Switches
Cylinder Rods
Always use solvents and paints in an area with Pumps and Motors
adequate ventilation. DO NOT use solvents or Wiring Harnesses or Connectors
paints near heat, fire, or electrical equipment
that can make sparks. Follow the paint manu-
facturer’s instructions and precautions. CAUTION
Protect electrical components, wiring, and
electrical contacts from overspray.
CAUTION
DO NOT put tape on cylinder rods to protect 4. Paint the surfaces using Hyster approved paints.
from paint. Use a thick layer of multipurpose Follow the proper paint scheme for your lift truck
grease to protect cylinder rods. Cylinders can model (refer to the Parts Manual for specific in-
be damaged if operated with tape on the cylin- formation on paint for your lift truck).
der rod.
5. Install new safety labels. See Safety Labels Re-
1. Clean the surface to be painted. Use a solvent placement.
on surfaces to be painted to remove grease and
oil before sanding. DO NOT use solvent to clean
new paint. Make sure all oil and grease is re-
moved.

12
100 SRM 1185 Safety Labels Replacement

Safety Labels Replacement

all air is removed from under the label or plate
WARNING and the corners and edges are tight. DO NOT
Safety labels are installed on the lift truck to attempt to move the label or plate once it has
give information about operation and possible been stuck down.
hazards. It is important that all safety labels
are installed on the lift truck and can be read.

DO NOT add to or modify the lift truck. Any

change to the lift truck, the tires, or its equip-
ment can change the lifting capacity. The lift
truck must be rated as equipped and the name-
plate must show the new capacity rating. Con-
tact your lift truck dealer for a replacement
nameplate.

Cleaning solvents can be flammable and toxic

and can cause skin irritation. When using
cleaning solvents, always follow the recom-
mendations of the manufacturer.

If an adhesive plate or label must be replaced, use

the following procedure to install a new label or plate.
See Figure 11 and Figure 12.

1. Clean area with an oil-free cleaner to remove all

oil, grease, and foreign matter. Wipe until com-
pletely dry.
1. MULTIFUNCTION CONTROL LABEL
2. Carefully remove only the paper backing from 2. NAMEPLATE
adhesive. DO NOT touch adhesive surface with 3. NAMEPLATE COVER
hands or remove front mask from label or plate 4. RIVET
face. 5. HYDRAULIC FUNCTION DECAL

3. Exposed adhesive face must be free from all for- Figure 11. Operator Compartment Label
eign matter before positioning label or plate on Placement
surface.

4. Press label or plate down firmly making sure that

all corners are stuck down tight. Make sure that

13
Safety Labels Replacement 100 SRM 1185

Figure 12. Label Placement

14
100 SRM 1185 Safety Labels Replacement

Legend for Figure 12

A. LEFT SIDE C. FRONT
B. RIGHT SIDE D. REAR
1. HYSTER LOGO LABEL 12. INFO CASE COVER
2. FORK WARNING LABEL 13. OPERATOR WARNING LABEL
3. PINCH WARNING LABEL 14. HYSTER LOGO DECAL
4. HYSTER NUMERALS DECAL 15. CRUSH WARNING LABEL
5. AC LABEL 16. FREEZER LABEL
6. HYSTER MATRIX LABEL 17. PATENT PLATE
7. BATTERY NOTICE LABEL 18. UL LABEL
8. RIVET 19. RIVET
9. INFO CASE BASE 20. EE LABEL
10. MOUNTING STRIP 21. NON-POWERED LOWERING LABEL (LOCATED
11. OVERHEAD GUARD WARNING DECAL INSIDE DOOR)

15
 NOTES

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 TECHNICAL PUBLICATIONS

100 SRM 1185 3/11 (11/08)(6/07)(11/06)(10/06) Printed in U.S.A.