Hyster A265 (N35-40ZRS, N30ZDRS) Reach Truck Service Manual
881 pages · Publication 1652265
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- Models
- A265 (N35-40ZRS, N30ZDRS)
- Manual type
- Service Manual
- Pages
- 881
- Publication
- 1652265
- Condition
- Brand new
What's inside
From the manual's own table of contents: 254 sections, 461 entries. See sample pages (PDF, 217 KB)
Lift Cylinders
Safety Precautions Maintenance and Repair
General
Description1 topic
- Lowering Control Valve
Main Cylinder Repair2 topics
- Disassemble
- Assemble
Free-Lift Cylinder Repair
Troubleshooting
Master Drive Unit
HFK400 Master Drive Unit4 topics
- General
- Description
- Drive Unit Maintenance and Repair
- Troubleshooting
GK Master Drive Unit3 topics
- Maintenance
- Remove
- Install
Table 1. Tooth Contact Pattern
Troubleshooting and Adjustments Using the AC Controls Program (E6 topics
- Computer Requirements
- Software, Install
- Language Selection
- Demo Mode
- Connect PC to Lift Truck
- Starting AC Controls Program
Lift Truck Control Setup6 topics
- Change Lift Truck Serial Number or Hourmeter
- Setting Factory Default Values or Changing Lift Truck Parameters
- Create New Custom Lift Truck Configuration
- Lift Truck Configuration Properties
- Import New Lift Truck Configuration From Disk
- Delete Custom Lift Truck Configuration or Password File
Dash Display3 topics
- Custom Display Languages
- Download Display Language
- Clear Operator Log
Password Functions5 topics
- Enable/Disable Password and Lift Truck Inspection Functions
- Password Properties
- Create New Password File
- Download Passwords
- Upload Passwords
Reports Menu8 topics
- Devices Report
- Custom Report
- Password Report
- Operator Report
- Current Settings Report
- Status Code Report
- Status Codes Log
- Diagnostics
Help Menu2 topics
- Technical Support
- About Electric Truck AC Controls Program
Frame
Repairs - General
Covers, Panels, and Plates7 topics
- Front Frame Panel (Left and Right)
- Operator Compartment Cover
- Drive Unit Compartment Door
- Door Pad
- Operator Back Pad
- Operator Front Pad
- Caster Wheel Cover
Load Wheels
Overhead Guard Replacement1 topic
- Front Lights
Painting Instructions
Safety Labels Replacement
Show all 254 sections
AC Motor Repair
Traction Motor Repair2 topics
- Inspect
- Drive End Bearing, Replace
Hydraulic Motor Repair
Table 1. Traction Motor Windings
Table 2. Hydraulic Motor Windings
Steering System2 topics
- Discharging the Capacitors
- Raising the Lift Truck
Steering Handle Assembly2 topics
- Fixed Handle
- Adjustable Handle
Steering Controller
Steering Proximity Switch1 topic
- Replace
Steering Motor
Caster Assembly - General1 topic
- Caster Adjustment
Caster Wheels
Caster Wheel Assembly (Nonsteered)
Caster Assembly (Steered)
Table 1. Caster Specifications
Table 2. Upper Adjustment Gap Measurement
Brake System
Introduction
Electric Brake1 topic
- Air Gap
Electrical System1 topic
- Static Strap
Battery Connection1 topic
- Replacing Cables
Key Switch
Contactors3 topics
- Function
- Testing
- EE Contactors
Motor Controllers1 topic
- Functions
Integrated Fuse Board (IFB)1 topic
- Fuses
Power Disconnect Switch
Side-Stance Controls1 topic
- Multifunction Control Handle
Forward-Stance Controls2 topics
- Control Handle Functions
- Aft Travel Control Handle Option
Steering Handle1 topic
- Steering Unit Repair
Foot Switches3 topics
- Brake Switch
- Operator Sensing
- Repair
Dash Display Assembly1 topic
- Test
Horn1 topic
- Audible Alarm
Light Assemblies2 topics
- Rear Work and Caution Light
- Light Switches
Cooling Fans2 topics
- Electrical Compartment Fans
- Operator Fan
Impact Sensor
Height Proximity Switch1 topic
- Adjust
Load Transport Proximity Switch
Fork Height Sensor Option
Reach Position Sensor
Retract Sensor
Tilt Leveling
Laser Option
Camera Option
Wiring Harness
User Interface1 topic
- Dash Display Menu Access
Menu Navigation1 topic
- Standard Display
Main Menu
Diagnostics Menu5 topics
- Static Diagnostics
- Traction System
- Hydraulic System
- Steer System
- Error Log
View Hourmeters
View Software Versions7 topics
- Master Controller
- Display
- Traction Controller
- Hydraulic Controller
- Control Handle
- Steer Controller
- Caster Controller
Passwords Menu3 topics
- Add Password
- Delete Password
- Edit Password
Table 1. Static Diagnostics Menu
Table 2. Traction System Diagnostics Menu
Table 3. Hydraulic System Diagnostics Menu
Table 4. Steering System Diagnostics Menu
Table 5. Error Log
Table 6. Master Controller Software Version
Table 7. Display Software Version
Table 8. Traction Controller Software Version
Table 9. Hydraulic Controller Software Version
Table 10. Control Handle Software Version
Table 11. Remote CAN Module Software Version
Table 12. Steer Controller Software Version
Table 13. Caster Controller Software Version
Table 14. Aux Pump Controller Software Version
Table 15. Impact Sensor Data Display5 topics
- General Truck
- Truck Hours
- Traction Hours
- Pump Hours
- Auxiliary Hours
Setup Menu5 topics
- Lift Settings
- Auxiliary Settings
- Steer Settings
- Truck Settings
- Traction Settings
Password Menu
Table 1. Password Screen
Table 2. Static Diagnostics Menu
Table 3. Traction System Diagnostics Menu
Table 4. Hydraulic System Diagnostics Menu
Table 5. Steering System Diagnostics Menu
Table 6. General Truck Diagnostics Menu
Table 7. Error Log
Table 8. Truck Hours
Table 9. Traction Hours
Table 10. Pump Hours
Table 11. Auxiliary Hours
Table 12. Lift Maximum Speed Menu
Table 13. Lower Maximum Speed Menu
Table 14. Fast Extend Speed Menu
Table 15. Slow Extend Speed Menu
Table 16. Fast Retract Speed Menu
Table 17. Slow Retract Speed Menu
Table 18. Tilt Up Speed Menu
Table 19. Tilt Down Speed Menu
Table 20. Sideshift Speed Menu
Table 21. Cushioning Speed Menu
Table 22. Steer Mode Menu
Table 23. Steer Effort Menu
Table 24. Steer Ratio Menu
Table 25. Truck Serial Number Menu
Table 26. Truck Voltage Menu
Table 27. Truck Capacity Menu
Table 28. Truck Type Menu
Table 29. BDI Adjust Menu
Table 30. Extended Shift Menu
Table 31. Lift Limit Without Override
Table 32. Lift Limit With Override
Table 33. Audible Alarm Menu
Table 34. Visible Alarm Menu
Table 35. Autotilt Option Menu
Table 36. Laser Option
Table 37. Carry Level Option Menu
Table 38. Restore Defaults Menu
Table 39. Simultaneous Hydraulics Menu
Table 40. Password Option Menu
Table 41. Shutdown Timeout Menu
Table 42. Rabbit Speed Menu
Table 43. Rabbit Acceleration Menu
Table 44. High Speed Menu
Table 45. High Acceleration Menu
Table 46. Mid Speed Menu
Table 47. Mid Acceleration Menu
Table 48. Turtle Speed Menu
Table 49. Turtle Acceleration Menu
Table 50. Neutral Braking Menu
Table 51. Plug Braking Menu
Table 52. Master Controller Software Version
Table 53. Display Software Version
Table 54. Traction Controller Software Version
Table 55. Hydraulic Controller Software Version
Table 56. Control Handle Software Version
Table 57. Remote CAN Module Software Version
Table 58. Steer Controller Software Version
Table 59. Caster Controller Software Version
Table 60. Aux Pump Controller Software Version
Table 61. Impact Sensor Data Display
Mast
Safety Procedures When Working Near Mast
Mast Weldments
Reach Carriage Assembly
Three-Stage Mast1 topic
- Operation
Load Backrest
Forks1 topic
- Checks
Sheaves
Hydraulic System1 topic
- Hydraulic Oil
Load Rollers5 topics
- Mast
- Reach Assembly
- Clean and Inspect
- Main Lift Cylinders
- Free-Lift Cylinder
Lift Chains
Mast Adjustments8 topics
- Mast Back Angle Adjustment
- Load Rollers Adjustment
- Adjust Wear Plugs - Mast
- Adjust Main-Lift Chains
- Adjust Free-Lift Chain
- Adjust Wear Strips
- Mast Racking
- Proximity Switches
Mast Operation Check
Lift System Leak Check2 topics
- Lift Cylinder Leak Check
- Tilt Cylinder Leak Check
Table 1. Fork Tip Alignment
Table 2. Cylinder Identification
Reach Carriages
Repair - General1 topic
- Replacement
Reach Carriage Assembly Repair
Load Rollers Repair
Side Rollers Repair (6.9 Mast Only) (N30ZDRS and N35-40ZRS)
Reach Assembly Front Frame4 topics
- Disassemble (With Sideshift)
- Disassemble (Without Sideshift)
- Assemble (With Sideshift)
- Assemble (Without Sideshift)
Single-Reach Scissor Arms2 topics
- Remove and Disassemble
- Assemble and Install
Double-Reach Scissor Arms
Rear Frame Assembly
Reach Cylinders
Tilt Cylinder1 topic
- Clean, Inspect, and Repair
Sideshift Cylinder
Front Selector Valve
Rear Selector Valve
Reach Assembly Adjustments5 topics
- Check Adjustment
- Adjust Side Rollers and Load Rollers
- Adjust Reach Cylinders
- Clean and Lubricate
- Adjust Free-Lift Chains
Specifications
Table 1. General Specifications
Table 2. Operating Times
Periodic Maintenance4 topics
- Removing Covers
- How to Move Disabled Truck
- How to Put Lift Truck on Blocks
- Manual Lowering Valve
Transporting2 topics
- Loading
- Unloading
Preparation for Use2 topics
- Preparation After Shipment
- Preparation After Storage
Maintenance Schedule
Maintenance Procedures Every 8 Hours or Daily2 topics
- Checks With Key Switch Turned OFF
- Checks With Key Switch Turned ON
Maintenance Procedures Every 500 Hours or 3 Months5 topics
- Master Drive Unit
- Hydraulic Filter Element Change
- Drive Tire Check
- Lift System Operation
- Other Lubrication
Maintenance Procedures Every 2000 Hours or Yearly2 topics
- Brakes
- Electric System
Lift and Tilt System Leaks Check2 topics
- Lift System
- Tilt System
Battery Maintenance2 topics
- How to Charge Battery
- How to Change Battery
Tires and Wheels4 topics
- Drive Tire
- How to Change Drive Tire
- Tandem Load Wheels
- Caster Wheels
Preparation for Storage2 topics
- Short-Term Storage (1 to 6 months)
- Long-Term Storage (6 months or longer)
Table 1. Maintenance Schedule
Table 2. Fork Tip Alignment
Table 3. Hydraulic Tank Capacities
Table 4. Caster Specifications
Table 5. Upper Adjustment Gap Measurement
Table 6. Free-Lift Cylinder Rod Widths
Table 7. Battery Size Specifications
Table 8. Tires and Wheels
Capacities and Specifications
Lubrication Specifications
Oil Capacities
Lift Specifications
Tire Sizes
Torque Specifications4 topics
- Reach Carriage
- Hydraulic System ( N30ZDRS and N35-40ZRS )
- Steering System
- Load Wheels
Fuses
Coil Resistance Values
Battery Specifications8 topics
- Truck
- Traction
- Pump
- Auxiliary
- Display Settings
- Remote CAN Module ( N35ZDR, N45ZR, N30ZDR, N35-40ZR Only)
- Aux Pump
- View Operator Log
Setup Shelf Height
Learn Shelf Height
Maintenance Reminder
Table 1. Enter Password Screen
Table 3. Traction System Menu
Table 4. Hydraulic System Menu
Table 5. Steer System Menu
Table 6. Impact Sensor Data Display
Table 6. General Truck Menu
Table 7. Impact Sensor Data Display
Control Handle2 topics
- Sidestance Control Handle
- Fore/Aft Stance
Maintenance7 topics
- Oil Level and Leaks
- Oil Change
- Breather Cap
- Oil Filter
- Oil Strainer
- Hoses
- Fittings
Lift Pump and Motor2 topics
- Complete Unit
- Lift Pump
Main Control Valve1 topic
- Manual Lowering
Auxiliary Hydraulics2 topics
- Front Selector Valve
- Rear Selector Valve
Hydraulic Tank
Table 1. Cylinder Identification
AC Motor Controllers/Display Panel
AC Transistor Motor Controller Replacement2 topics
- General Maintenance Instructions
- Contactors
Master Controller Checks and Adjustments
Function Settings4 topics
- Controller Status Light Emitting Diodes (LEDs)
- Operator Status Messages
- Status Codes
- Checking the Motor Controller
Display Panel
Standard Display Functions and Features5 topics
- Key-On Initialization
- Passwords
- Performance Modes
- Battery Discharge Indicator (BDI)
- Hourmeters
Standard Dash Display Service Menu Navigation4 topics
- Moving Through Menu Selections
- Editing and Adding Information
- Access to Service Functions
- Service Functions
Premium Display Functions and Features3 topics
- Operator Checklist Function
- Battery Discharge Indicator
- Shelf Height Selector
Premium Dash Display Service Menu Navigation
Connector Pin-Outs
System Logic Diagram
Table 1. Factory Parameter Defaults
Table 2. Traction Parameter Defaults
Table 3. List of Operator Warning Messages
Table 4. List of Fault Messages
Table 5. Password Prompt Screen
Table 6. Password Prompt Screen
Table 7. Password Prompt Screen
Table 8. Password Prompt Screen
Table 9. Password Screen
Table 10. Password Prompt Screen
Table 11. Password Prompt Screen
Inside this manual
Real pages from this service manual (881 pages). Open the sample pages (PDF, 216 KB)
- Specifications, page 584: Maintenance Procedures Every 2000 Hours or Yearly
- Diagram, page 662: Figure 2. Schematic/Wiring Diagram After October, 2008 (Sheet 14 of 26)
- Troubleshooting, page 779: Troubleshooting
This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 881 pages
Quantity one is the manual described above.
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Ships in 1 business day.
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Binder not included
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Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).