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Yale Lift Truck Type AD (B815): NDR030, NR035, NR040, NR045; AE (B816) NS040, NS050 Workshop Manual
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:
NDR 030 AD
NR 035 AD
NR 040 AD
NR 045 AD
NS 040 AE
NS 050 AE
Format: PDF, 331 Pages
Language: English
Contents:
1 OPERATING INSTRUCTIONS
OPERATING INSTRUCTIONS-GENERAL
SAFETY LABELS
OPERATOR PRE-CHECKS AND INSPECTION
OPERATING PROCEDURE-GENERAL
SHUT DOWN PROCEDURE
FORK ADJUSTMENT
SAFETYAND 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
EVERY 350 HOURS
EVERY 2000 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
AUXILIARY SWITCH
TESTING
REMOVAL
INSTALLATION
EE CONTACTORS
FUSES
RELAYS
DESCRIPTION/FEATURES
ENABLE
HOUR METER
COIL TESTING
CONTACT TESTING
REMOVAL AND INSTALLATION
HEIGHT LIMIT SWITCH
REMOVAL
TESTING
INSTALLATION
KEY SWITCH
REMOVAL
INSTALLATION
BATTERY DISCONNECT SWITCH
REMOVAL
INSTALLATION
PROPORTIONAL ELECTRO-HYDRAULIC VALVES
MANUAL LOWERING
OPERATION
SELECTOR VALVES
TESTING/REMOVAUINSTALLATION
MULTI-FUNCTION CONTROL HANDLE
DESCRIPTION/FEATURES
OPERATION
DISASSEMBLY
ASSEMBLY
TRACTION AND HYDRAULIC POTENTIOMETER
TESTING
INSTALLATION
ADJUSTMENT
MAIN INTERFACE BOARD (MIB)
DESCRIPTION/FEATURES
OPERATION
LED DISPLAY
REMOVAL
INSTALLATION
MAIN INTERFACE BOARD ADJUSTMENTS
GENERAL
DEFAULT VALUES
CHECKING THE MODEL CODE AND SET-UP STATUS
MIB CALIBRATION PROCEDURE
STEP 1 ENTER THE SET-UP MODE
STEP 2 ERASE THE MODEL CODE
STEP 3 SET THE MODEL CODE
STEP 4 CALIBRATE HYDRAULIC POTENTIOMETER RANGE ..
STEP 5 CALIBRATE TRACTION POTENTIOMETER RANGE ..
STEP 6 EXIT THE SET-UP MODEAND SAVE NEW VALUES ..
CUSTOMIZING MIB FUNCTIONS
MIB FUNCTION DESCRIPTIONS
MIB PLUG PIN IDENTIFICATION
MIB STATUS, WARNING AND FAULT CODES
GENERAL
TROUBLESHOOTING CHARTS
MIB BLANK OR UNDEFINED CODES
MIB STATUS CODES
MIB WARNING CODES
MIB FAULT CODES
TRACTION MOTOR CONTROLLER
DESCRIPTION/FEATURES
REMOVAL
TESTING
INSTALLATION
PROGRAMMER HAND SET
DESCRIPTION/FEATURES
SCROLL DISPLAY KEYS
CHANGE VALUE KEYS
MORE INFO KEY
OPERATION
CONNECTING THE HAND SET TO THE
TRACTION MOTOR CONTROLLER
DISCONNECTING THE HAND SET FROM THE
TRACTION MOTOR CONTROLLER
PROGRAMMER SELF TEST
OPERATING MODES
PROGRAM MENU
TEST MENU
DIAGNOSTICS MENU
DIAGNOSTIC HISTORY
SPECIAL PROGRAM MENU
PROGRAMMING THE TRACTION MOTOR CONTROLLER
TROUBLESHOOTING
STATUS LED DIAGNOSTICS
PROGRAMMER DIAGNOSTICS
TEST MENU
DIAGNOSTICS MENU
DASH DISPLAY ASSEMBLY
DESCRIPTION/FEATURES
OPERATION
REMOVAL
INSTALLATION
VOLTAGE SELECTION
ADJUSTMENT
TROUBLESHOOTING
INOPERATIVE DASH DISPLAY ASSEMBLY
INOPERATIVE DRIVE MODE SELECTION
TROUBLESHOOTING WITH A PROGRAMMER HAND SET
TROUBLESHOOTING WITHOUT A PROGRAMMER HAND SET
NO WARNINGS OR FAULTS DISPLAYED
LIFT INTERRUPT
LOST MIB SIGNAL DISPLAYED
HOURMETER INPUT
MOTOR MAINTENANCE-GENERAL
BRUSHAND COMMUTATOR INSPECTION
NORMAL COMMUTATOR SURFACES
COMMUTATOR PROBLEMS
BRUSH REPLACEMENT-TRACTION AND HYDRAULIC MOTORS
COMMUTATOR REPAIRS
TESTS
DAMAGED FIELD AND ARMATURE
SHORT-CIRCUIT IN AN 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
MAIN INTERFACE BOARD (MIB) FUNCTION CODE VALUES
24V NR035AD
24VNR040AD .
36V NR035AD
36V NR040AD
36V NR045AD
24V NDR030AD
36V NDR030AD
24V NS040AE
36V NS040AE
36VNS050AE
WIRING DIAGRAMS AND SCHEMATICS
WIRING SCHEMATIC 5241353-87
OPTIONS SCHEMATIC 5241353-87
WIRING DIAGRAM5241353-87
OPTIONS DIAGRAM 5241353-87
4 DRIVE UNIT
GENERAL
DESCRIPTION
ARTICULATION STOP ADJUSTMENT
ARTICULATION ADJUSTMENT PROCEDURE
AXLE ASSEMBLY
TRACTION MOTOR
REMOVAL
INSTALLATION
HYDRAULIC STEERING MOTOR
DESCRIPTION
REMOVAL
INSTALLATION
REPAIR
REMOVAL-ARTICULATING AXLE WELDMENT
INSTALLATION-ARTICULATING AXLE WELDMENT
MASTER DRIVE UNIT
DESCRIPTION
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
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
BRAKE ADJUSTMENT
REMOVE AIR 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 BRACKET ASSEMBLY
REMOVAL AND DISASSEMBLY
ASSEMBLY AND INSTALLATION
STEERING PUMP AND MOTOR
STEERING PUMP SPECIFICATIONS
REMOVAL-PUMP AND MOTOR
ASSEMBLY AND INSTALLATION-PUMP AND MOTOR
DISASSEMBLY-STEERING PUMP
ASSEMBLY-STEERING PUMP
CHECKS AND ADJUSTMENTS
REMOVEAIR FROM STEERING SYSTEM
STEERING PRESSURE ADJUSTMENT
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
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
MAIN LIFT CHAINS
TRIPLEX CHAIN SHEAVES-DISASSEMBLY AND ASSEMBLY
FREE LIFT CHAIN SHEAVES
MAIN LIFT 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-WTTH 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 FROMHYDRAULIC 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 MAIN LIFT CHAINS
SIMPLEX:
TRIPLEX:
CARRIAGE OR REACHASSEMBLY ADJUSTMENTS
ADJUST WEAR PLUG
ADJUST SIDEROLLERS
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
11 ALPHABETICAL INDEX
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