Yale NDR030AD, NR035AD, NR040AD, NR045AD, NS040AE, NS050AE Lift Truck B815, B816 Ser. Service Manual

Original Illustrated Factory Workshop Service maintenance Manual for Yale Lift Truck Type B815 Models NDR030AD, NR035AD, NR040AD, NR045AD; Type B816 Models NS040AE, NS050AE

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:
   NDR030AD
   NR035AD
   NR040AD
   NR045AD
   NS040AE
   NS050AE

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
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