Original Illustrated Factory Workshop Service Manual for Yale Electric Reach Truck.

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-TRACTID 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