Yale Narrow Aisle Reach Truck A861: NDR030GA, NDR045GA, NR030GA, NR045GA Service Manual

Original Illustrated Factory Workshop Service Manual for Yale Narrow Aisle Reach Truck Type A861.

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:
NDR030GA
NDR045GA
NR030GA
NR045GA

Format: PDF, 321 Pages
Language: English

Contents:
1 OPERATING INSTRUCTIONS
    OPERATING INSTRUCTIONS-GENERAL
    SAFETY LABELS
    OPERATOR PRE-CHECKS AND INSPECTION
    OPERATING PROCEDURE-GENERAL
    SHUT DOWN PROCEDURE
    FORKADJUSTMENT
    SAFETYAND OPERATIONAL CHECK LIST
    MODEL AND OPERATING INFORMATION
    SAFE MAINTENANCE PROCEDURES
    MOVINGA DISABLED 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
    WIRE GUARD
    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
    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
    BOLTS AND SCREWS
    STUDS AND NUTS
    TORQUE NUTS
    TORQUE NUTS WITH NYLON INSERTS
    GENERAL GUIDE TO TORQUE VALUES
    RECOMMENDED MAXIMUM TORQUE VALUES FOR HYDRAULIC
    FITTINGS
    CONVERSION TABLE FOR METRICAND ENGLISH UNITS
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
    SIDACTOR
    RELAYS
    DESCRIPTION/FEATURES
    ENABLE
    HOURMETER
    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 CONTROL VALVES
    DESCRIPTION/FEATURES
    MANUAL LOWERING
    OPERATION
    SELECTOR VALVES
    TESTING/REMOVAL/INSTALLATION
    MULTIFUNCTION CONTROL HANDLE
    DESCRIPTION/FEATURES
    OPERATION
    DISASSEMBLY
    ASSEMBLY
    TRACTION AND HYDRAULIC POTENTIOMETER
    TESTING
    INSTALLATION
    ADJUSTMENT
    MAIN INTERFACE BOARD (MIB)
    DESCRIPTION/FEATURES
    OPERATION
    LED DISPLAY
    MIB REMOVAL
    MIB INSTALLATION
    MAIN INTERFACE BOARD ADJUSTMENTS
    GENERAL
    DEFAULT VALUES
    CHECKING MODEL CODEAND SET-UPSTATUS
    MIB CALIBRATION PROCEDURE
    STEP1 ENTERING THE SET-UP MODE
    STEP 2 ERASING THE MODEL CODE
    STEP 3 SETTING THE MODEL CODE
    STEP 4 CALIBRATING HYDRAULIC POTENTIOMETER RANGE
    STEP 5 CALIBRATING TRACTION POTENTIOMETER RANGE .
    STEP 6 EXITING THE SET-UP MODEAND SAVING THE
    NEW VALUES
    CUSTOMIZING MIB FUNCTIONS
    MIB FUNCTION DESCRIPTIONS
    MIB FUNCTION CODE VALUES
    MIB STATUS, WARNING AND FAULT CODES
    TROUBLESHOOTING CHARTS
    MIB PLUG PIN IDENTIFICATION
    DASH DISPLAYASSEMBLY
    DESCRIPTION/FEATURES
    OPERATION
    TESTING
    INOPERATIVE DASH DISPLAYASSEMBLY
    INOPERATIVE DRIVE MODE SELECTION
    TROUBLESHOOTING WITH A PROGRAMMER HANDSET
    TROUBLESHOOTING WITHOUTA PROGRAMMER HANDSET . .
    NO WARNINGS OR FAULTS DISPLAYED
    MIB/DASHDISPLAY COMMUNICATION
    LIFT INTERRUPT
    LOST MIB SIGNAL DISPLAYED
    HOURMETER INPUT
    FORWARD/REVERSE INPUTS
    REMOVAL
    INSTALLATION
    ADJUSTMENT (SETUP)
    TRACTION MOTOR CONTROLLER
    DESCRIPTION/FEATURES
    REMOVAL
    TESTING
    INSTALLATION
    PROGRAMMER HANDSET
    DESCRIPTION/FEATURES
    SCROLL DISPLAY KEYS
    CHANGE VALUE KEYS
    MORE INFO KEY
    OPERATION
    CONNECTING THE HANDSET TO THE
    TRACTION MOTOR CONTROLLER
    DISCONNECTING THE HANDSET 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
    MOTOR MAINTENANCE-GENERAL
    BRUSHAND COMMUTATOR INSPECTION
    NORMAL COMMUTATOR SURFACES
    COMMUTATOR PROBLEMS
    BRUSH REPLACEMENT-TRACTIONAND HYDRAULIC MOTORS
    COMMUTATOR REPAIRS
    TESTS
    DAMAGED FIELD AND ARMATURE
    SHORT CIRCUIT INAN ARMATURE WINDING
    SHORT CIRCUIT IN THE ARMATURE
    OPEN CIRCUIT INA FIELD COIL
    SHORT CIRCUIT INA FIELD COIL
    SHORT CIRCUIT BETWEEN FIELD AND MOTOR CASE
    BRUSH HOLDER
    WIRING SCHEMATIC 524135978 36 VOLT TYPE "E" (A861)
    WIRING SCHEMATIC 524138370 36 VOLT TYPE "E" (C829)
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-ARTICULATINGAXLE WELDMENT
    INSTALLATION-ARTICULATING AXLE WELDMENT
    MASTER DRIVE UNIT
    DESCRIPTION
    REMOVAL
    INSTALLATION
    DISASSEMBLY
    ASSEMBLY
    TROUBLESHOOTING
5 BRAKE SYSTEM
    GENERAL (C829)
    BRAKEASSEMBLY (C829)
    REMOVAL AND DISASSEMBLY
    ASSEMBLY AND INSTALLATION
    MASTER CYLINDER AND PEDAL ASSEMBLY (0829)
    REMOVAL AND DISASSEMBLY
    ASSEMBLY AND INSTALLATION
    FLOOR PLATEASSEMBLY (C829 & A861)
    REMOVAL AND DISASSEMBLY
    ASSEMBLY AND INSTALLATION
    MASTER CYLINDER (C829 &A861)
    DISASSEMBLY
    ASSEMBLY
    SLAVE CYLINDER (C829 & A861)
    DISASSEMBLY
    ASSEMBLY
    BRAKE SWITCH-REPLACE (C829)
    CHECKS AND ADJUSTMENTS (0829)
    BRAKEADJUSTMENT
    REMOVEAIR FROM THE BRAKE SYSTEM
    TROUBLESHOOTING
    GENERAL (A861)
    ELECTRIC BRAKEASSEMBLY
    REMOVAL AND DISASSEMBLY
    ASSEMBLY AND INSTALLATION
    CASTER BRAKEASSEMBLY (A861)
    REMOVAL AND DISASSEMBLY
    ASSEMBLY AND INSTALLATION
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 PUMP AND 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
    CARRIAGE ASSEMBLY
    REACHASSEMBLIES
    LOAD BACKREST EXTENSION
    REMOVAL AND INSTALLATION
    FORK REPLACEMENT
    HOOK FORKS
    SHAFT FORKS
    HOOK FORK CARRIAGE ASSEMBLY-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 REACH SCISSOR ARMS
    REMOVAL AND DISASSEMBLY
    CLEANING AND INSPECTION
    ASSEMBLY AND INSTALLATION
    DOUBLE REACH SCISSOR ARMS
    REMOVAL AND DISASSEMBLY
    CLEANING AND INSPECTION
    ASSEMBLY AND INSTALLATION
    INNER FRAMEASSEMBLY
    REMOVAL
    DISASSEMBLY
    ASSEMBLY
    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 SHEAVES 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-DISASSEMBLYAND ASSEMBLY.
    FREE LIFT CHAIN SHEAVES
    MAINLIFT CHAIN SHEAVES
    LOAD ROLLERSAND WEAR PLUGS
    REMOVAL AND INSTALLATION
    TRIPLEX MASTASSEMBLY-INSTALLATION
    REACH CYLINDERS
    REMOVAL
    CLEANING AND INSPECTION
    DISASSEMBLY
    CLEANING AND INSPECTION
    ASSEMBLY
    INSTALLATION
    TILT CYLINDER AND TILT PIVOTMECHANISM
    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
    ADJUST MAINLIFT CHAINS
    TRIPLEX
    CARRIAGE OR REACHASSEMBLY ADJUSTMENTS
    ADJUST WEAR PLUG
    ADJUST SIDE ROLLERS
    ADJUST THRUST ROLLERS
    ADJUST REACH CYLINDERS
    ADJUST TILT CYLINDER
    ADJUST 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 BATTERYAS A COUNTERWEIGHT
    THE NEWBATTERY
    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
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