Yale NDR030AC/BC, NR035/040/045AC, NR035/045BC, NS040/050AD Reach Truck Service Maintenance Manual

Original Illustrated Factory Workshop Service Manual for Yale Electric Reach Truck models NDR030AC, NDR030BC, NR035AC, NR035BC, NR040AC, NR045AC, NR045BC, NS040AD, NS050AD

Original factory manuals for Yale Forklift Trucks, contains high quality images, circuit diagrams and instructions to help you to operate and repair your truck. All Manuals Printable and contains Searchable Text

Covered models:
NDR030AC
NDR030BC
NR035AC
NR035BC
NR040AC
NR045AC
NR045BC
NS040AD
NS050AD

Format: PDF, 355 Pages
Language: English

Contents:
    1 OPERATING INSTRUCTIONS
        OPERATING INSTRUCTIONS-GENERAL
        SAFETY LABELS
        OPERATOR PRE-CHECKSAND INSPECTION
        OPERATING PROCEDURE-GENERAL
        SHUT DOWN PROCEDURE
        FORKADJUSTMENT
        SAFETY AND OPERATIONAL CHECKLIST
        MODEL AND OPERATING INFORMATION
        SAFE MAINTENANCE PROCEDURES
        MOVING A DISABLED LIFT TRUCK
        HOW TO TOW A LIFT TRUCK
        HOW TO PUTA LIFT TRUCK ON BLOCKS
        HOW TO RAISE THE LOAD WHEELS
        HOW TO RAISE THE DRIVE/STEER TIRE AND CASTER WHEELS .
        PRECAUTIONS FOR TRUCKS IN STORAGE
        PRECAUTIONS FOR BATTERIES IN STORAGE
    2 GENERAL TRUCK AND LUBRICATION SCHEDULE
        GENERAL
        FRAME
        LOAD BACKRESTAND FORKS
        MAST SCREEN
        ACCESS DOOR AND COVERS
        OVERHEAD GUARD
        BATTERY COMPARTMENT
        CHANGING THE BATTERY
        TIRES AND WHEELS
        SOLID TIRES
        REMOVE THE ONE PIECE WHEEL AND TIRE
        INSTALL THE TIRE ON THE ONE PIECE WHEEL
        INSTALL THE WHEELS ON THE LIFT TRUCK
        TANDEM LOAD WHEELS
        REMOVAL-TANDEM LOAD WHEELS
        INSTALLATION-TANDEM LOAD WHEELS
        SINGLE LOAD WHEELS
        REMOVAL-SINGLE LOAD WHEELS
        INSTALLATION-SINGLE LOAD WHEELS
        CASTER AND CASTER WHEELS
        DESCRIPTION
        REMOVAL-CASTER
        INSTALLATION-CASTER
        REMOVAL-CASTER WHEELS
        INSTALLATION-CASTER WHEELS
        ARTICULATION STOP ADJUSTMENT
        ADJUSTMENT PROCEDURE
        YALE WARRANTY INFORMATION
        RECOMMENDED SCHEDULES OF MAINTENANCE (ALL MODELS)
        LUBRICATION INSTRUCTIONS
        EVERY350 HOURS
        EVERY2000 HOURS
        HYDRAULIC OILS
        GEAR OILS
        BRAKE FLUID
        GREASE
        ANTI-SEIZE LUBRICATING COMPOUND
        FASTENERS-INTRODUCTION
        THREADS, NOMENCLATURE
        STRENGTH IDENTIFICATION
    3 ELECTRICAL SYSTEM
        INTRODUCTION
        GENERAL
        COMPONENT REPAIR AND TESTING
        GENERAL
        CONTACTOR PANEL ASSEMBLY
        DESCRIPTION/FEATURES
        REMOVAL
        INSTALLATION
        CONTACTORS
        DESCRIPTION/FEATURES
        TESTING
        REMOVAL
        INSTALLATION
        °EE'''' CONTACTORS
        FUSES
        RELAYS
        DESCRIPTION/FEATURES
        HOUR METER
        ENABLE
        TRACTION
        COIL TESTING
        CONTACT TESTING
        REMOVAL AND INSTALLATION
        HEIGHTLIMIT SWITCH
        REMOVAL
        TESTING
        INSTALLATION
        KEY SWITCH
        REMOVAL
        INSTALLATION
        BATTERY DISCONNECT SWITCH
        REMOVAL
        INSTALLATION
        PROPORTIONAL ELECTRO-HYDRAULIC VALVES
        DESCRIPTION/FEATURES
        ELECTRO-HYDRAULIC CONTROL VALVE-MANUAL LOWERING
        OPERATION
        SELECTOR VALVES
        TESTING/REMOVAL/INSTALLATION
        MULTI-FUNCTION CONTROL HANDLE
        DESCRIPTION/FEATURES
        OPERATION
        DISASSEMBLY
        ASSEMBLY
        TRACTION AND HYDRAULIC POTENTIOMETER
        TESTING
        INSTALLATION
        ADJUSTMENT
        MAININTERFACE BOARD (MIB)
        DESCRIPTION/FEATURES
        OPERATION
        DISPLAY
        PRIORITIES
        REMOVAL
        INSTALLATION
        CHECKING THE MODEL CODEAND SET-UP STATUS
        DEFAULT VALUES
        CUSTOM PROGRAMMING
        MAIN INTERFACE BOARD ADJUSTMENTS
        GENERAL
        MIB SET-UP SEQUENCE
        MIB SET-UP PROCEDURE
        INCREASING/DECREASING THE FUNCTION NUMBER
        INCREASING/DECREASING THE FUNCTION VALUE
        STEP 1 ENTERING THE SET-UP MODE
        STEP 2 ERASING THE MODEL CODE
        STEP 3 SETTING THE MODEL CODE
        STEP 4 HYDRAULIC POTENTIOMETER SET-UP
        STEP 5 TRACTION POTENTIOMETER SET-UP
        STEP 6 EXITING THE SET-UP MODE
        EXITAND SAVE NEW VALUES
        MIB FUNCTION DESCRIPTIONS
        MIB CODES
        MIB STATUS CODES
        MIB WARNING CODES
        MIB FAULT CODES
        STATUS, WARNING AND FAULT CODE TROUBLESHOOTING
        DASH DISPLAYASSEMBLY
        DESCRIPTION/FEATURES
        OPERATION
        TESTING
        INOPERATIVE DASH DISPLAYASSEMBLY
        INOPERATIVE DRIVE MODESELECTION
        TROUBLESHOOTING WITH A PROGRAMMER HAND SET
        TROUBLESHOOTING WITHOUTA PROGRAMMER HAND SET .
        NO WARNINGS OR FAULTS DISPLAYED
        MIB/DASH DISPLAY COMMUNICATION
        LIFT INTERRUPT
        LOST MIB SIGNAL DISPLAYED
        HOURMETER INPUT
        FORWARD/REVERSE INPUTS
        REMOVAL
        INSTALLATION
        ADJUSTMENT (SET-UP)
        VOLTAGE SELECTION
        PROGRAMMER HAND SET
        DESCRIPTION/FEATURES
        SCROLL DISPLAY KEYS
        CHANGE VALUE KEYS
        MORE INFO KEY
        PROGRAM MENU
        TEST MENU
        DIAGNOSTICS MENU
        SPECIAL PROGRAM MENU
        DIAGNOSTIC HISTORY
        PROGRAMMER SELF TEST
        CONNECTING THE HAND SET TO THE
        TRACTION MOTOR CONTROLLER
        DISCONNECTING THE HAND SET FROM THE
        TRACTION MOTOR CONTROLLER
        TRACTION MOTOR CONTROLLER
        DESCRIPTION/FEATURES
        REMOVAL
        INSTALLATION
        TESTING
        BENCH TEST SET-UP FOR PROGRAMMING
        PROGRAMMING THE TRACTION MOTOR CONTROLLER
        PROGRAM MENU
        TEST MENU
        DIAGNOSTICS MENU
        TRANSISTORIZED MOTOR CONTROLLERS
        THEORY OF OPERATION
        BASIC CONTROLLER OPERATION
        MOTOR CIRCUIT THAT OPERATES WITH PULSES
        FIELD EFFECT TRANSISTOR (FET)
        INDUCTION CURRENT FROM THE MOTOR
        PLUGGING CIRCUIT
        CONTROL CIRCUIT
        SRO (STATIC-RETURN-TO-OFF) FUNCTION
        THERMAL PROTECTION FUNCTION
        LOW VOLTAGE PROTECTION FUNCTION
        CURRENT LIMIT PROTECTION FUNCTION
        POWER CIRCUIT
        MOTOR MAINTENANCE-GENERAL
        BRUSHAND COMMUTATOR INSPECTION
        NORMAL COMMUTATOR SURFACES
        COMMUTATOR PROBLEMS
        BRUSH REPLACEMENT-TRACTIONAND HYDRAULIC MOTORS
        COMMUTATOR REPAIRS
        TESTS
        DAMAGED FIELDAND ARMATURE
        SHORT-CIRCUIT INAN ARMATURE WINDING
        SHORT-CIRCUIT IN THE ARMATURE
        OPEN CIRCUIT INA FIELD COIL
        SHORT-CIRCUIT INA FIELD COIL
        SHORT-CIRCUIT BETWEEN FIELDAND MOTOR CASE
        BRUSH HOLDER
        WIRING SCHEMATIC 5049907-00 - TYPE ''''E'''' AND ''''EE'''' NR/NDR/NS WITHOUT TR'''' (TRACTION CUTOUT RELAY)
        OPTIONAL WIRING SCHEMATIC 5049907-00 - TYPE ''''E'''' AND ''''EE'''' NR/NDR/NS WITHOUT `TR'''' (TRACTION CUTOUT RELAY)
        WIRING DIAGRAM 5049907-00 - TYPE ''''E'''' AND ''''EE'''' NR/NDR/NS WITHOUT ''''TR'''' (TRACTION CUTOUT RELAY)
        OPTIONAL WIRING DIAGRAM5049907-00 - TYPE ''''E'''' AND ''''EE'''' NR/NDR/NS WITHOUT TR'''' (TRACTION CUTOUT RELAY)
        WIRING SCHEMATIC 5047947-00 - TYPE ''''E'''' NR/NDR/NS WITH TR'''' (TRACTION CUTOUT RELAY)
        OPTIONAL WIRING SCHEMATIC 5047947-00 - TYPE ''''E'''' NR/NDR/NS WITH TR'''' (TRACTION CUTOUT RELAY)
        WIRING DIAGRAM5047947-00 - TYPE ''''E'''' NR/NDR/NS WITH TR'''' (TRACTION CUTOUT RELAY)
        OPTIONAL WIRING DIAGRAM 5047947-00 - TYPE ''''E'''' NR/NDR/NS WITH TR'''' (TRACTION CUTOUT RELAY)
        WIRING SCHEMATIC 5048857-00 - TYPE ''''EE'''' NR/NDR/NS WITH TR'''' (TRACTION CUTOUT RELAY)
        OPTIONAL WIRING SCHEMATIC 5048857-00 - TYPE ''''EE'''' NR/NDR/NS WITH TR'''' (TRACTION CUTOUT RELAY)
        WIRING DIAGRAM5048857-00 - TYPE ''''EE'''' NR/NDR/NS WITH TR'''' (TRACTION CUTOUT RELAY)
        OPTIONAL WIRING DIAGRAM 5048857-00 - TYPE ''''EE'''' NR/NDR/NS WITH TR'''' (TRACTION CUTOUT RELAY)
    4 DRIVE UNIT
        GENERAL
        DESCRIPTION
        ARTICULATION STOP ADJUSTMENT
        ARTICULATION ADJUSTMENT PROCEDURE
        AXLE ASSEMBLY
        TRACTION MOTOR
        REMOVAL-TRACTION MOTOR
        INSTALLATION-TRACTION MOTOR
        HYDRAULIC STEERING MOTOR
        DESCRIPTION
        HYDRAULIC STEERING MOTOR-REMOVAL
        HYDRAULIC STEERING MOTOR-INSTALLATION
        REPAIR
        REMOVAL-ARTICULATING AXLE WELDMENT
        INSTALLATION-ARTICULATING AXLE WELDMENT
        MASTER DRIVE UNIT
        DESCRIPTION
        REMOVAL-MASTER DRIVE UNIT
        INSTALLATION-MASTER DRIVE UNIT
        DISASSEMBLY
        ASSEMBLY
        BEVEL PINION SHAFT-INSTALLATION
        BEVEL GEAR-INSTALLATION
        INSTALLATION
        CHECKS AND ADJUSTMENTS
        ADJUST BACKLASH AND TOOTH CONTACT PATTERN
        ADJUST BEARING CLEARANCE
        CHECK TRUNNION BEARING
        TROUBLESHOOTING
    5 BRAKE SYSTEM
        GENERAL
        BRAKEASSEMBLY
        REMOVAL AND DISASSEMBLY
        ASSEMBLY AND INSTALLATION)
        MASTER CYLINDER AND PEDAL ASSEMBLY
        REMOVAL AND DISASSEMBLY
        ASSEMBLY AND INSTALLATION
        FLOOR PLATEASSEMBLY
        REMOVAL AND DISASSEMBLY
        ASSEMBLY AND INSTALLATION
        MASTER CYLINDER
        DISASSEMBLY
        ASSEMBLY
        SLAVE CYLINDER
        DISASSEMBLY
        ASSEMBLY
        BRAKE SWITCH-REPLACE
        CHECKS AND ADJUSTMENTS
        BRAKEADJUSTMENT
        REMOVEAIR FROM THE BRAKE SYSTEM
        TROUBLESHOOTING
    6 STEERING SYSTEM
        STEERING SYSTEM-INTRODUCTION
        HYDRAULIC STEERING MOTOR
        DESCRIPTION
        REMOVAL
        INSTALLATION
        STEERING CONTROL UNIT
        REMOVAL
        INSTALLATION
        DISASSEMBLY
        CLEANING
        ASSEMBLY
        STEERING TILLER MOUNTING BRACKETASSEMBLY
        REMOVAL AND DISASSEMBLY
        ASSEMBLY AND INSTALLATION
        STEERING PUMP AND MOTOR
        STEERING PUMP SPECIFICATIONS
        REMOVAL-PUMPAND MOTOR
        ASSEMBLY AND INSTALLATION-PUMP AND MOTOR
        DISASSEMBLY-STEERING PUMP
        ASSEMBLY-STEERING PUMP
        CHECKS AND ADJUSTMENTS
        REMOVEAIR FROM STEERING SYSTEM
        STEERING PRESSUREADJUSTMENT
        TROUBLESHOOTING
    7 HYDRAULIC SYSTEM
        HYDRAULIC SYSTEM-INTRODUCTION
        SPECIFICATIONS
        ELECTRO-HYDRAULIC CONTROL VALVE
        ELECTRO-HYDRAULIC CONTROL VALVE-MANUAL LOWERING
        HOIST PUMP
        STEER PUMP
        HOIST PUMPAND MOTOR
        REMOVAL
        INSTALLATION
        HOIST PUMP
        DISASSEMBLY
        ASSEMBLY
        HYDRAULIC CONTROL VALVE
        REMOVAL
        INSTALLATION
        DISASSEMBLY
        ASSEMBLY
        HYDRAULIC TANK
        REMOVAL
        INSTALLATION
        TROUBLESHOOTING
    8 MAST AND REACH ASSEMBLY
        MASTS
        CARRIAGEASSEMBLY
        REACHASSEMBLIES
        LOAD BACKREST EXTENSION
        REMOVAL AND INSTALLATION
        FORK REPLACEMENT
        HOOKFORKS-NS
        PIN FORKS-NR OR NDR
        CARRIAGEASSEMBLY-REMOVAL AND INSTALLATION
        REACHASSEMBLY-REMOVAL AND INSTALLATION
        CARRIAGE LOAD ROLLERS
        REMOVAL AND INSTALLATION
        SIDE ROLLERS-DISASSEMBLYAND ASSEMBLY
        REPAIR-REACHASSEMBLY
        REACHASSEMBLY OUTER FRAME
        REMOVAL WITH SIDESHIFTER
        DISASSEMBLY
        CLEANING AND INSPECTION
        ASSEMBLY
        INSTALLATION
        REMOVAL WITHOUT SIDESHIFTER
        DISASSEMBLY WITHOUT SIDESHIFTER
        CLEANING AND INSPECTION
        ASSEMBLY WITHOUT SIDESHIFTER
        INSTALLATION WITHOUT SIDESHIFTER
        SINGLE REACHSCISSOR ARMS
        REMOVAL AND DISASSEMBLY
        CLEANING AND INSPECTION
        ASSEMBLYAND INSTALLATION
        DOUBLE REACH SCISSOR ARMS
        REMOVAL AND DISASSEMBLY
        CLEANING AND INSPECTION
        ASSEMBLY AND INSTALLATION
        INNER FRAMEASSEMBLY
        REMOVAL
        DISASSEMBLY. ...
        ASSEMBLY
        INSTALLATION
        SIMPLEX MASTASSEMBLY
        REMOVAL
        CLEANING AND INSPECTION
        LIFT CYLINDERS-REMOVAL AND INSTALLATION
        INNER MASTASSEMBLY-REMOVAL AND INSTALLATION
        HOSES-REPLACE
        HOSEAND CABLE SHEAVES-REPLACE
        SIMPLEX LIFT CHAINS-REMOVAL AND INSTALLATION
        CLEANING AND INSPECTION
        SIMPLEX CHAIN SHEAVE-REMOVAL AND INSTALLATION
        LOAD ROLLERS AND WEAR PLUGS
        REMOVAL AND INSTALLATION
        INSTALLATION
        TRIPLEX MASTASSEMBLY
        REMOVAL
        CLEANING AND INSPECTION
        FREE LIFT CYLINDER-REMOVAL AND INSTALLATION
        MAIN CYLINDERS-REMOVAL AND INSTALLATION
        INNER AND INTERMEDIATE MASTASSEMBLIES
        REMOVAL AND INSTALLATION
        HOSES-REPLACE
        HOSEAND CABLE SHEAVE REPLACE
        FREE LIFT HOSE SHEAVE
        CARRIAGE OR REACH SHEAVES
        REMOVAL AND REPLACEMENT
        TRIPLEX LIFT CHAIN REMOVAL AND INSTALLATION
        FREE LIFT CHAINS
        MAINLIFT CHAINS
        TRIPLEX CHAIN SHEAVES-DISASSEMBLY AND ASSEMBLY
        FREE LIFT CHAIN SHEAVES
        MAINLIFT CHAIN SHEAVES
        LOAD ROLLERS AND WEAR PLUGS
        REMOVAL AND INSTALLATION
        TRIPLEX MASTASSEMBLY-INSTALLATION
        REACH CYLINDERS
        REMOVAL
        CLEANING AND INSPECTION
        DISASSEMBLY
        CLEANING AND INSPECTION
        ASSEMBLY
        INSTALLATION
        TILT CYLINDER AND TILT PIVOT MECHANISM
        REMOVAL-WITH SIDESHIFTER
        REMOVAL-WITHOUT SIDESHIFTER
        DISASSEMBLY
        CLEANING AND INSPECTION
        ASSEMBLY ..
        INSTALLATION-WITH SIDESHIFTER
        INSTALLATION-WITHOUT SIDESHIFTER
        SIDESHIFT CYLINDER
        REMOVAL
        DISASSEMBLY
        CLEANING AND INSPECTION
        ASSEMBLY
        INSTALLATION
        REACH/TILT SELECTOR VALVE
        REMOVAL
        DISASSEMBLY
        CLEANING AND INSPECTION
        ASSEMBLY
        INSTALLATION
        TILT/SIDESHIFT SELECTOR VALVE
        REMOVAL
        DISASSEMBLY
        CLEANING AND INSPECTION
        ASSEMBLY
        INSTALLATION
        CHECKS AND ADJUSTMENTS
        CHECK MAST OPERATION
        REMOVEAIR FROM HYDRAULIC SYSTEM
        CHECK FOR LEAKS IN HYDRAULIC SYSTEM
        CHECK LIFT CHAINS
        CLEANING AND INSPECTION
        LUBRICATION
        MASTADJUSTMENTS
        ADJUST WEAR PLUGS
        ADJUST WEAR STRIPS
        ADJUST FREE LIFT CHAIN (TRIPLEX ONLY)
        ADJUST MAINLIFT CHAINS
        SIMPLEX:
        TRIPLEX:
        CARRIAGE OR REACHASSEMBLY ADJUSTMENTS
        ADJUST WEAR PLUG
        ADJUST SIDE ROLLERS
        ADJUST THRUST ROLLERS
        ADJUSTMENT FOR THE REACH CYLINDERS
        ADJUSTMENT FOR THE TILT CYLINDER
        ADJUSTMENT FOR THE SIDESHIFT CYLINDER
        TROUBLESHOOTING-MAST
        TROUBLESHOOTING-REACH AND CARRIAGE
        SPECIFICATIONS
    9 BATTERY AND CHARGING SYSTEM
        BATTERYAND CHARGING SYSTEM-GENERAL
        SAFETY TIPS FOR HANDLING INDUSTRIAL TRUCK BATTERIES
        BATTERY TROUBLESHOOTING
        BATTERY TROUBLESHOOTING
        LEAD-ACID BATTERIES
        SPECIFIC GRAVITY
        CHEMICAL REACTION
        HOW TO SELECT THE BATTERY
        VOLTAGE OFA BATTERY
        BATTERY RATINGS
        KILOWATT HOURS
        THE BATTERY AS A COUNTERWEIGHT
        THE NEW BATTERY
        BATTERY MAINTENANCE
        MAINTENANCE RECORDS
        CLEANING THE BATTERY
        ADDING WATER
        HYDROMETER
        BATTERY TEMPERATURE
        CHARGING THE BATTERY
        TYPES OF BATTERY CHARGES
        METHODS OF CHARGING
        TROUBLESHOOTING THE CHARGER
        HOW TO KNOW WHEN THE BATTERY IS FULLY CHARGED
        BATTERY CHARGING AREA
        EQUIPMENT NEEDED
    10 USER SUPPORT INFORMATION
        SERVICE PARTS ORDERING INSTRUCTIONS
        TECHNICAL PUBLICATIONS
        PARTS MANUAL
        OPERATING MANUAL
        OPERATOR TRAINING
        SERVICE TRAINING COURSES
        SERVICE TRAINING MATERIALS
    11 ALPHABETICAL INDEX