Hyster yale A295 Service Manual – PDF DOWNLOAD

Description

Hyster yale A295 Service Manual – PDF DOWNLOAD

DESCRIPTION:

Hyster yale A295 Service Manual – PDF DOWNLOAD

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair
on electric lift trucks. Disconnect the battery ground cable on internal combustion lift
trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance
section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit whenmaking repairs,
or if the unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.

TABLE OF CONTENTS:

Hyster yale A295 Service Manual – PDF DOWNLOAD

524150797-8000YRM0231-(12-2004)-US-EN...............................................  1
	toc.............................................................................  1
		Metric and Inch (SAE) Fasteners.............................................  1
		Safety Precautions Maintenance and Repair...................................  2
		General.....................................................................  5
			Threaded Fasteners......................................................  5
			Nomenclature, Threads...................................................  5
			Strength Identification.................................................  6
			Cotter (Split) Pins.....................................................  6
			Fastener Torque Tables.................................................. 11
			Conversion Table........................................................ 13
	tables..........................................................................  1
		Table 1. Bolts and Screws...................................................  7
		Table 2. Studs and Nuts.....................................................  8
		Table 3. Torque Nuts........................................................  9
		Table 4. Torque Nuts with Nylon Insert...................................... 10
		Table 5. Torque Values for Metric Fasteners*................................ 11
		Table 6. Torque Values for Inch Fasteners*.................................. 12
		Table 7. Conversion Table for Metric and English Units...................... 13
		Table 8. Cotter Pin Dimensional Data........................................ 14
		Table 9. Cotter Pin Dimensional Data........................................ 15
		Table 10. Cotter Pin Dimensional Data....................................... 16
		Table 11. Cotter Pin Dimensional Data....................................... 18
524158040-2240YRM0001-(02-2008)-US-EN............................................... 21
	toc............................................................................. 21
		Industrial Battery.......................................................... 21
		Safety Precautions Maintenance and Repair................................... 22
		General..................................................................... 25
		Lead-Acid Batteries......................................................... 25
		Specific Gravity............................................................ 26
		Chemical Reaction in a Cell................................................. 26
		Electrical Terms............................................................ 27
		Battery Selection........................................................... 28
		Battery Voltage............................................................. 29
		Battery as a Counterweight.................................................. 29
		Battery Ratings............................................................. 30
			Kilowatt-Hours.......................................................... 30
		Battery Maintenance......................................................... 30
			Safety Procedures....................................................... 30
			Maintenance Records..................................................... 31
			New Battery............................................................. 31
			Cleaning Battery........................................................ 31
			Adding Water to Battery................................................. 33
			Hydrometer.............................................................. 34
			Battery Temperature..................................................... 34
			Charging Battery........................................................ 35
				Types of Battery Charges............................................ 36
				Methods of Charging................................................. 37
				Troubleshooting Charger............................................. 38
				Knowing When Battery Is Fully Charged............................... 38
			Where to Charge Batteries............................................... 38
				Equipment Needed.................................................... 38
			Battery Connectors...................................................... 39
			Battery Care............................................................ 39
	tables.......................................................................... 21
		Table 1. Battery Capacity Terms............................................. 30
524164473-4000YRM0481-(04-2008)-US-EN............................................... 43
	toc............................................................................. 43
		Lift Cylinders.............................................................. 43
		Safety Precautions Maintenance and Repair................................... 44
		General..................................................................... 47
		Description................................................................. 47
			Lowering Control Valve.................................................. 48
		Main Cylinder Repair........................................................ 49
			Disassemble............................................................. 49
			Assemble................................................................ 50
		Free-Lift Cylinder Repair................................................... 52
			Disassemble............................................................. 52
			Assemble................................................................ 52
		Troubleshooting............................................................. 53
524166250-0630YRM1022-(11-2006)-US-EN............................................... 57
	toc............................................................................. 57
		Master Drive Unit........................................................... 57
		Safety Precautions Maintenance and Repair................................... 58
		HFK400 Master Drive Unit.................................................... 61
			General................................................................. 61
			Description............................................................. 61
			Drive Unit Maintenance and Repair....................................... 62
				Remove.............................................................. 62
				Install............................................................. 63
				Disassemble......................................................... 64
				Assemble............................................................ 67
			Troubleshooting......................................................... 75
		GK Master Drive Unit........................................................ 77
			General................................................................. 77
			Description............................................................. 77
			Maintenance and Repair.................................................. 78
			Install................................................................. 79
			Assemble................................................................ 79
				Mounting Electric Motor............................................. 80
				Pivoted Connection - Geared Steering................................ 80
			Disassemble............................................................. 80
			Troubleshooting......................................................... 81
	tables.......................................................................... 57
		Table 1. Tooth Contact Pattern.............................................. 72
524183085-2200YRM1058-(09-2008)-US-EN............................................... 85
	toc............................................................................. 85
		Troubleshooting and Adjustments Using the AC Controls Program (E............ 85
		Safety Precautions Maintenance and Repair................................... 86
		General..................................................................... 89
			Computer Requirements................................................... 89
			Software, Install....................................................... 89
			Language Selection...................................................... 89
			Demo Mode............................................................... 90
			Connect PC to Lift Truck................................................ 94
			Starting AC Controls Program............................................ 96
		Lift Truck Control Setup....................................................101
			Change Lift Truck Serial Number or Hourmeter............................101
			Setting Factory Default Values or Changing Lift Truck Parameters........103
			Create New Custom Lift Truck Configuration..............................109
			Lift Truck Configuration Properties.....................................112
			Import New Lift Truck Configuration From Disk...........................115
			Delete Custom Lift Truck Configuration or Password File.................117
		Dash Display................................................................120
			Custom Display Languages................................................120
			Download Display Language...............................................122
			Clear Operator Log......................................................122
		Password Functions..........................................................125
			Enable/Disable Password and Lift Truck Inspection Functions.............125
				Truck Inspection Checklist..........................................125
				Password............................................................125
			Password Properties.....................................................125
			Create New Password File................................................125
			Download Passwords......................................................132
			Upload Passwords........................................................132
		Reports Menu................................................................136
			Devices Report..........................................................136
			Custom Report...........................................................136
			Password Report.........................................................136
			Operator Report.........................................................144
			Current Settings Report.................................................148
			Status Code Report......................................................152
			Status Codes Log........................................................155
		Troubleshooting.............................................................157
			Diagnostics.............................................................157
		Help Menu...................................................................160
			General.................................................................160
			Contents................................................................160
			Technical Support.......................................................160
			About Electric Truck AC Controls Program................................160
524233332-1600YRM1187-(02-2009)-US-EN...............................................167
	toc.............................................................................167
		Steering System.............................................................167
		Safety Precautions Maintenance and Repair...................................168
		General.....................................................................171
			Discharging the Capacitors..............................................172
			Raising the Lift Truck..................................................173
				How to Raise the Drive Tire End.....................................173
				How to Raise the Entire Lift Truck..................................174
		Description.................................................................174
		Steering Handle Assembly....................................................177
			Fixed Handle............................................................177
				Description.........................................................177
				Remove..............................................................177
				Disassemble.........................................................179
				Assemble............................................................179
				Install.............................................................179
			Adjustable Handle.......................................................181
				Description.........................................................181
				Remove..............................................................181
				Disassemble.........................................................181
				Assemble............................................................185
				Install.............................................................185
		Steering Controller.........................................................186
			Description.............................................................186
			Remove..................................................................186
			Disassemble.............................................................187
			Assemble................................................................187
			Install.................................................................187
		Steering Proximity Switch...................................................187
			Replace.................................................................187
		Steering Motor..............................................................188
			Description.............................................................188
			Remove..................................................................188
			Disassemble.............................................................189
			Assemble................................................................189
			Install.................................................................189
		Caster Assembly - General...................................................190
			Caster Adjustment.......................................................190
				Elastomer Spring Type Adjustment....................................190
				Belleville Spring Type Adjustment...................................191
				Spring Pack Replacement.............................................192
					Remove Spring Assembly..........................................192
					Replace Spring Pack.............................................193
					Install Spring Assembly.........................................194
		Caster Wheels...............................................................194
			Remove..................................................................194
			Install.................................................................195
		Caster Wheel Assembly (Nonsteered)..........................................195
			Description.............................................................195
			Remove..................................................................195
			Disassemble.............................................................197
				Upper and Lower Support Housings....................................197
				Spring Assembly From Lower Support Assembly.........................197
				Caster Spindle From Lower Support...................................197
				Caster Wheels.......................................................198
				Lower Support Housing...............................................199
				Upper Support Housing...............................................200
			Assemble................................................................200
				Upper Support Housing...............................................200
				Lower Support Housing...............................................201
				Caster Wheels.......................................................202
				Caster Spindle to Lower Support.....................................202
				Spring Assembly to Lower Support....................................202
				Upper and Lower Support Housings....................................203
			Install.................................................................203
		Caster Assembly (Steered)...................................................204
			Description.............................................................204
			Remove..................................................................204
			Disassemble.............................................................206
				Upper and Lower Support.............................................206
				Spring Assembly From Lower Support Housing..........................206
				Caster Spindle From Lower Support...................................206
				Caster Wheels.......................................................207
				Lower Support Housing...............................................208
				Upper Support Housing...............................................209
				Caster Steering Motor...............................................210
			Assemble................................................................210
				Caster Steering Motor...............................................210
				Upper Support Housing...............................................210
				Lower Support Housing...............................................211
				Caster Wheels.......................................................212
				Caster Spindle to Lower Support.....................................212
				Spring Assembly to Lower Support....................................213
				Upper and Lower Support Housings....................................213
			Install.................................................................213
		Troubleshooting.............................................................214
	tables..........................................................................167
		Table 1. Caster Specifications..............................................191
		Table 2. Upper Adjustment Gap Measurement...................................192
524233333-0100YRM1185-(11-2008)-US-EN...............................................217
	toc.............................................................................217
		Frame.......................................................................217
		Safety Precautions Maintenance and Repair...................................218
		General.....................................................................221
		Description.................................................................221
		Repairs - General...........................................................221
			Welding.................................................................222
		Covers, Panels, and Plates..................................................222
			Front Frame Panel (Left and Right)......................................222
			Operator Compartment Cover..............................................223
			Drive Unit Compartment Door.............................................223
			Door Pad................................................................223
			Operator Back Pad.......................................................223
				Side-Stance Models..................................................223
				Forward-Stance Models...............................................223
			Operator Front Pad......................................................224
			Caster Wheel Cover......................................................224
		Load Wheels.................................................................224
			Remove..................................................................224
			Install.................................................................224
		Overhead Guard Replacement..................................................225
			Remove..................................................................227
			Install.................................................................227
			Front Lights............................................................229
				Bulb Replacement....................................................229
				Assembly Replacement................................................230
				Rear Work and Caution Light.........................................231
				Caution Light.......................................................231
		Painting Instructions.......................................................232
		Safety Labels Replacement...................................................233
524233334-0620YRM1186-(11-2006)-US-EN...............................................239
	toc.............................................................................239
		AC Motor Repair.............................................................239
		Safety Precautions Maintenance and Repair...................................240
		General.....................................................................243
		Traction Motor Repair.......................................................244
			Disassemble.............................................................244
			Inspect.................................................................244
			Assemble................................................................245
			Drive End Bearing, Replace..............................................246
		Hydraulic Motor Repair......................................................247
			Disassemble.............................................................247
			Inspect.................................................................248
			Assemble................................................................249
		Troubleshooting.............................................................249
	tables..........................................................................239
		Table 1. Traction Motor Windings............................................245
		Table 2. Hydraulic Motor Windings...........................................249
524233335-1800YRM1188-(05-2008)-US-EN...............................................253
	toc.............................................................................253
		Brake System................................................................253
		Safety Precautions Maintenance and Repair...................................254
		Introduction................................................................257
			General.................................................................257
			Discharging the Capacitors..............................................257
		Electric Brake..............................................................258
			Air Gap.................................................................259
			Remove..................................................................260
			Install.................................................................260
		Troubleshooting.............................................................261
524233338-2200YRM1191-(11-2008)-US-EN...............................................265
	toc.............................................................................265
		Electrical System...........................................................265
		Safety Precautions Maintenance and Repair...................................266
		General.....................................................................271
			Discharging the Capacitors..............................................272
			Static Strap............................................................272
				Inspect.............................................................272
				Replace.............................................................272
		Battery Connection..........................................................273
			Inspect.................................................................273
			Replacing Cables........................................................273
		Key Switch..................................................................274
			Replace.................................................................274
		Contactors..................................................................276
			Function................................................................276
			Testing.................................................................277
			Remove..................................................................277
			Install.................................................................278
			EE Contactors...........................................................278
		Motor Controllers...........................................................279
			Functions...............................................................279
				Master Controller...................................................279
				Steering Motor Controller...........................................279
				Traction Motor Controller...........................................279
				Lift Motor Controller...............................................279
				Steer Caster Controller (Optional)..................................279
			Replace.................................................................279
				Traction and Lift Motor Controllers.................................280
				Master Controller...................................................280
				Steering Controller.................................................280
				Steer Caster Controller (Option)....................................281
		Integrated Fuse Board (IFB).................................................281
			Fuses...................................................................282
			Replace.................................................................282
		Power Disconnect Switch.....................................................283
			Replace.................................................................283
		Side-Stance Controls........................................................284
			Multifunction Control Handle............................................284
			Remove..................................................................285
			Disassemble.............................................................285
			Assemble................................................................287
			Install.................................................................287
		Forward-Stance Controls.....................................................288
			Control Handle Functions................................................288
				Repair..............................................................288
			Aft Travel Control Handle Option........................................290
				Repair..............................................................291
		Steering Handle.............................................................292
			Steering Unit Repair....................................................292
		Foot Switches...............................................................296
			Brake Switch............................................................296
			Operator Sensing........................................................296
			Repair..................................................................296
		Dash Display Assembly.......................................................297
			Description.............................................................297
			Remove..................................................................298
			Test....................................................................299
			Install.................................................................299
		Horn........................................................................300
			Audible Alarm...........................................................300
		Light Assemblies............................................................301
			Front Lights............................................................301
				Bulb Replacement....................................................301
				Assembly Replacement................................................301
			Rear Work and Caution Light.............................................302
				Rear Work Light.....................................................302
				Caution Light.......................................................302
			Light Switches..........................................................303
		Cooling Fans................................................................305
			Electrical Compartment Fans.............................................305
				Replace.............................................................305
			Operator Fan............................................................307
				Repair..............................................................307
		Impact Sensor...............................................................309
			Remove..................................................................309
			Install.................................................................309
		Height Proximity Switch.....................................................310
			Test....................................................................310
			Remove..................................................................310
			Install.................................................................311
			Adjust..................................................................311
		Load Transport Proximity Switch.............................................312
			Replace.................................................................312
			Adjust..................................................................313
		Fork Height Sensor Option...................................................313
			Remove..................................................................313
				Encoder Assembly....................................................313
				Timing Belt.........................................................314
			Install.................................................................315
				Encoder Assembly....................................................315
				Timing Belt.........................................................316
		Reach Position Sensor.......................................................316
			Remove..................................................................316
			Install.................................................................318
		Retract Sensor..............................................................319
			Remove..................................................................319
			Install.................................................................319
		Tilt Leveling...............................................................321
			Remove..................................................................321
			Install.................................................................321
		Laser Option................................................................322
			Remove..................................................................322
			Install.................................................................322
		Camera Option...............................................................323
			Remove..................................................................323
			Install.................................................................323
		Wiring Harness..............................................................323
524233339-2200YRM1192-(11-2008)-US-EN...............................................331
	toc.............................................................................331
		User Interface..............................................................331
		Safety Precautions Maintenance and Repair...................................332
		General.....................................................................335
			Description.............................................................335
			Dash Display Menu Access................................................335
		Menu Navigation.............................................................336
			Standard Display........................................................336
		Main Menu...................................................................336
		Diagnostics Menu............................................................337
			Static Diagnostics......................................................337
			Traction System.........................................................341
			Hydraulic System........................................................342
			Steer System............................................................345
			Error Log...............................................................346
		View Hourmeters.............................................................346
		View Software Versions......................................................346
			Master Controller.......................................................346
			Display.................................................................347
			Traction Controller.....................................................347
			Hydraulic Controller....................................................348
			Control Handle..........................................................348
			Remote CAN Module ( NDR035EA, NR045EA, NDR030EA, NR035/040EA )..........349
			Steer Controller........................................................349
			Caster Controller.......................................................350
			Aux Pump................................................................350
		Impact Sensor...............................................................351
			Functions...............................................................352
				Impact Action.......................................................352
				Impact Sound........................................................352
				Clear Impact........................................................352
				Hard Duration.......................................................352
				Hard Acceleration...................................................352
				Soft Duration.......................................................352
				Soft Acceleration...................................................353
				Impact Events.......................................................353
		Passwords Menu..............................................................353
			Add Password............................................................354
			Delete Password.........................................................355
			Edit Password...........................................................356
	tables..........................................................................331
		Table 1. Static Diagnostics Menu............................................337
		Table 2. Traction System Diagnostics Menu...................................341
		Table 3. Hydraulic System Diagnostics Menu..................................342
		Table 4. Steering System Diagnostics Menu...................................345
		Table 5. Error Log..........................................................346
		Table 6. Master Controller Software Version.................................346
		Table 7. Display Software Version...........................................347
		Table 8. Traction Controller Software Version...............................347
		Table 9. Hydraulic Controller Software Version..............................348
		Table 10. Control Handle Software Version...................................348
		Table 11. Remote CAN Module Software Version................................349
		Table 12. Steer Controller Software Version.................................349
		Table 13. Caster Controller Software Version................................350
		Table 14. Aux Pump Controller Software Version..............................350
		Table 15. Impact Sensor Data Display........................................351
524233340-2200YRM1193-(11-2008)-US-EN...............................................359
	toc.............................................................................359
		User Interface..............................................................359
		Safety Precautions Maintenance and Repair...................................360
		General.....................................................................363
			Description.............................................................363
			Dash Display Menu Access................................................363
		Menu Navigation.............................................................364
			Standard Display........................................................364
		Main Menu...................................................................364
		Diagnostics Menu............................................................364
			Static Diagnostics......................................................364
			Traction System.........................................................368
			Hydraulic System........................................................369
			Steer System............................................................372
			General Truck...........................................................373
			Error Log...............................................................374
		View Hourmeters.............................................................374
			Truck Hours.............................................................374
			Traction Hours..........................................................375
			Pump Hours..............................................................375
			Auxiliary Hours.........................................................376
		Setup Menu..................................................................376
			Lift Settings...........................................................376
				Lift Maximum Speed ( NDR035EA, NR045EA, NDR030EA, NR035/040EA ).....376
				Lower Maximum Speed ( NDR035EA, NR045EA, NDR030EA, NR035/040EA )....377
			Auxiliary Settings......................................................377
				Fast Extend Speed...................................................377
				Slow Extend Speed...................................................378
				Fast Retract Speed..................................................378
				Slow Retract Speed..................................................379
				Tilt Up Speed.......................................................379
				Tilt Down Speed.....................................................380
				Sideshift Speed.....................................................380
				Reach Cushioning....................................................381
			Steer Settings..........................................................381
				Steer Mode..........................................................381
				Steer Effort........................................................382
				Steer Ratio.........................................................382
			Truck Settings..........................................................383
				Truck Serial Number.................................................383
				Truck Voltage.......................................................383
				Truck Capacity......................................................384
				Battery Type........................................................384
				BDI Adjust Calibration..............................................385
				Extended Shift......................................................385
				Lift Limit Without Override ( NDR035EA, NR045EA, NDR030EA, NR035....386
				Lift Limit With Override ( NDR035EA, NR045EA, NDR030EA, NR035/04....386
				Audible Alarm.......................................................387
				Visible Alarm.......................................................388
				Autotilt Option.....................................................388
				Laser Option........................................................389
				Carry Level Option..................................................389
				Slow Extended.......................................................390
				Simultaneous Hydraulics.............................................390
				Password Option.....................................................391
				Shutdown Timeout....................................................391
			Traction Settings.......................................................392
				Rabbit Speed........................................................392
				Rabbit Acceleration.................................................392
				High Speed..........................................................393
				High Acceleration...................................................393
				Mid Speed...........................................................394
				Mid Acceleration....................................................394
				Turtle Speed........................................................395
				Turtle Acceleration.................................................395
				Neutral Braking.....................................................396
				Plug Braking........................................................396
		View Software Versions......................................................397
			Master Controller.......................................................397
			Display.................................................................397
			Traction Controller.....................................................398
			Hydraulic Controller....................................................398
			Control Handle..........................................................399
			Remote CAN Module ( NDR035EA, NR045EA, NDR030EA, NR035/040EA )..........399
			Steer Controller........................................................400
			Caster Controller.......................................................400
			Aux Pump................................................................401
		Impact Sensor...............................................................402
			Functions...............................................................402
			Functions...............................................................403
				Impact Action.......................................................403
				Impact Sound........................................................403
				Clear Impact........................................................403
				Hard Duration.......................................................403
				Hard Acceleration...................................................403
				Soft Duration.......................................................403
				Sort Acceleration...................................................403
				Impact Events.......................................................403
		Password Menu...............................................................404
			Add Password............................................................405
			Delete Password.........................................................406
			Edit Password...........................................................407
	tables..........................................................................359
		Table 1. Password Screen....................................................363
		Table 2. Static Diagnostics Menu............................................365
		Table 3. Traction System Diagnostics Menu...................................368
		Table 4. Hydraulic System Diagnostics Menu..................................369
		Table 5. Steering System Diagnostics Menu...................................372
		Table 6. General Truck Diagnostics Menu.....................................373
		Table 7. Error Log..........................................................374
		Table 8. Truck Hours........................................................374
		Table 9. Traction Hours.....................................................375
		Table 10. Pump Hours........................................................375
		Table 11. Auxiliary Hours...................................................376
		Table 12. Lift Maximum Speed Menu...........................................376
		Table 13. Lower Maximum Speed Menu..........................................377
		Table 14. Fast Extend Speed Menu............................................377
		Table 15. Slow Extend Speed Menu............................................378
		Table 16. Fast Retract Speed Menu...........................................378
		Table 17. Slow Retract Speed Menu...........................................379
		Table 18. Tilt Up Speed Menu................................................379
		Table 19. Tilt Down Speed Menu..............................................380
		Table 20. Sideshift Speed Menu..............................................380
		Table 21. Cushioning Speed Menu.............................................381
		Table 22. Steer Mode Menu...................................................381
		Table 23. Steer Effort Menu.................................................382
		Table 24. Steer Ratio Menu..................................................382
		Table 25. Truck Serial Number Menu..........................................383
		Table 26. Truck Voltage Menu................................................383
		Table 27. Truck Capacity Menu...............................................384
		Table 28. Truck Type Menu...................................................384
		Table 29. BDI Adjust Calibration Menu.......................................385
		Table 30. Extended Shift Menu...............................................385
		Table 31. Lift Limit Without Override.......................................386
		Table 32. Lift Limit With Override..........................................386
		Table 33. Audible Alarm Menu................................................387
		Table 34. Visible Light Alarm Menu..........................................388
		Table 35. Autotilt Option Menu..............................................388
		Table 36. Laser Option......................................................389
		Table 37. Carry Level Option Menu...........................................389
		Table 38. Restore Defaults Menu.............................................390
		Table 39. Simultaneous Hydraulics Menu......................................390
		Table 40. Password Option Menu..............................................391
		Table 41. Shutdown Timeout Menu.............................................391
		Table 42. Rabbit Speed Menu.................................................392
		Table 43. Rabbit Acceleration Menu..........................................392
		Table 44. High Speed Menu...................................................393
		Table 45. High Acceleration Menu............................................393
		Table 46. Mid Speed Menu....................................................394
		Table 47. Mid Acceleration Menu.............................................394
		Table 48. Turtle Speed Menu.................................................395
		Table 49. Turtle Acceleration Menu..........................................395
		Table 50. Neutral Braking Menu..............................................396
		Table 51. Plug Braking Menu.................................................396
		Table 52. Master Controller Software Version................................397
		Table 53. Display Software Version..........................................397
		Table 54. Traction Controller Software Version..............................398
		Table 55. Hydraulic Controller Software Version.............................398
		Table 56. Control Handle Software Version...................................399
		Table 57. Remote CAN Module Software Version................................399
		Table 58. Steer Controller Software Version.................................400
		Table 59. Caster Controller Software Version................................400
		Table 60. Aux Pump Controller Software Version..............................401
		Table 61. Impact Sensor Data Display........................................402
524233341-4000YRM1194-(11-2006)-US-EN...............................................411
	toc.............................................................................411
		Mast........................................................................411
		Safety Precautions Maintenance and Repair...................................412
		General.....................................................................415
		Safety Procedures When Working Near Mast....................................417
		Mast Weldments..............................................................418
		Reach Carriage Assembly.....................................................418
		Three-Stage Mast............................................................420
			Description.............................................................420
			Operation...............................................................421
524233342-4000YRM1195-(11-2006)-US-EN...............................................425
	toc.............................................................................425
		Mast........................................................................425
		Safety Precautions Maintenance and Repair...................................426
		General.....................................................................429
		Safety Procedures When Working Near Mast....................................429
		Load Backrest...............................................................430
			Remove..................................................................430
			Install.................................................................430
		Forks.......................................................................431
			Remove..................................................................431
			Install.................................................................431
			Checks..................................................................432
		Sheaves.....................................................................432
		Hydraulic System............................................................436
			Hydraulic Oil...........................................................437
				Drain...............................................................437
				Cylinder Identification.............................................439
				Fill................................................................440
					Main Lift Cylinders.............................................440
					Free-Lift Cylinders.............................................441
		Reach Carriage Assembly.....................................................442
			Remove..................................................................442
			Install.................................................................443
		Load Rollers................................................................444
			Mast....................................................................444
			Reach Assembly..........................................................446
				Load Rollers........................................................446
				Side Rollers........................................................446
		Mast........................................................................447
			Remove..................................................................447
			Disassemble.............................................................448
			Clean and Inspect.......................................................449
			Assemble................................................................450
			Install.................................................................451
		Lift Cylinders..............................................................452
			Main Lift Cylinders.....................................................452
				Remove..............................................................453
				Install.............................................................453
			Free-Lift Cylinder......................................................456
				Remove..............................................................456
				Install.............................................................458
		Lift Chains.................................................................459
			Clean and Inspect.......................................................459
		Mast Adjustments............................................................460
			General.................................................................460
			Mast Back Angle Adjustment..............................................460
			Load Rollers Adjustment.................................................461
				Reach Carriage Assembly.............................................461
			Adjust Wear Plugs - Mast................................................462
			Adjust Main-Lift Chains.................................................463
			Adjust Free-Lift Chain..................................................463
			Adjust Wear Strips......................................................465
			Mast Racking............................................................466
			Proximity Switches......................................................467
				Replace.............................................................467
					Free-Lift Proximity Switch......................................467
					Load Lowering Proximity Switch (Optional).......................468
				Adjust..............................................................469
		Mast Operation Check........................................................469
		Lift System Leak Check......................................................469
			Lift Cylinder Leak Check................................................469
			Tilt Cylinder Leak Check................................................470
	tables..........................................................................425
		Table 1. Fork Tip Alignment.................................................432
		Table 2. Cylinder Identification............................................440
524233343-4500YRM1196-(10-2007)-US-EN...............................................473
	toc.............................................................................473
		Reach Carriages.............................................................473
		Safety Precautions Maintenance and Repair...................................474
		General.....................................................................477
		Safety Procedures When Working Near Mast....................................477
		Description.................................................................478
		Repair - General............................................................480
		Load Backrest...............................................................480
			Remove..................................................................480
			Install.................................................................480
		Forks.......................................................................481
			Replacement.............................................................481
				Remove..............................................................481
				Install.............................................................481
		Reach Carriage Assembly.....................................................482
			Remove..................................................................482
			Inspect.................................................................483
			Install.................................................................483
		Reach Carriage Assembly Repair..............................................485
		Load Rollers Repair.........................................................485
		Side Rollers Repair (6.9 Mast Only) (NDR030DA and NR035/040DA)..............486
		Reach Assembly Front Frame..................................................487
			Remove..................................................................487
			Disassemble (With Sideshift)............................................488
			Disassemble (Without Sideshift).........................................490
			Clean and Inspect.......................................................491
			Assemble (With Sideshift)...............................................491
			Assemble (Without Sideshift)............................................491
			Install.................................................................491
		Single-Reach Scissor Arms...................................................492
			Remove and Disassemble..................................................492
			Clean and Inspect.......................................................495
			Assemble and Install....................................................495
		Double-Reach Scissor Arms...................................................497
			Disassemble.............................................................497
			Clean and Inspect.......................................................500
			Assemble................................................................500
		Rear Frame Assembly.........................................................502
			Remove..................................................................502
			Disassemble.............................................................504
			Clean and Inspect.......................................................505
			Assemble................................................................505
			Install.................................................................505
		Reach Cylinders.............................................................506
			Remove..................................................................506
			Disassemble.............................................................508
			Clean and Inspect.......................................................508
			Assemble................................................................509
			Install.................................................................509
		Tilt Cylinder...............................................................510
			Remove..................................................................510
			Clean, Inspect, and Repair..............................................510
			Install.................................................................510
		Sideshift Cylinder..........................................................512
			Repair..................................................................512
		Front Selector Valve........................................................513
		Rear Selector Valve.........................................................514
		Reach Assembly Adjustments..................................................515
			Check Adjustment........................................................515
			Adjust Side Rollers and Load Rollers....................................516
			Adjust Reach Cylinders..................................................517
		Lift Chains.................................................................518
			Inspect.................................................................518
			Clean and Lubricate.....................................................519
			Adjust Main-Lift Chains.................................................519
			Adjust Free-Lift Chains.................................................519
		Specifications..............................................................521
		Troubleshooting ............................................................524
	tables..........................................................................473
		Table 1. General Specifications.............................................521
		Table 2. Operating Times ...................................................522
524233344-8000YRM1197-(02-2009)-US-EN...............................................529
	toc.............................................................................529
		Periodic Maintenance........................................................529
		Safety Precautions Maintenance and Repair...................................530
		General.....................................................................533
			Removing Covers.........................................................533
				Front Frame Panel (Left and Right)..................................533
				Operator Compartment Cover..........................................534
				Drive Unit Compartment Door.........................................535
				Caster Wheel Cover..................................................535
			Discharging the Capacitors..............................................535
			How to Move Disabled Truck..............................................536
				How to Tow Lift Truck...............................................536
			How to Put Lift Truck on Blocks.........................................537
				How to Raise Load Wheels............................................537
				How to Raise the Drive Tire End.....................................537
				How to Raise the Entire Lift Truck..................................538
			Manual Lowering Valve...................................................539
				NDR030/035EA and NR030/040/045EA....................................539
				NDR030DA and NR035/040DA............................................539
		Transporting................................................................540
			Loading.................................................................540
			Unloading...............................................................540
		Preparation for Use.........................................................541
			Preparation After Shipment..............................................541
			Preparation After Storage...............................................541
		Safety Procedures When Working Near Mast....................................541
		Maintenance Schedule........................................................542
		Maintenance Procedures Every 8 Hours or Daily...............................546
			Checks With Key Switch Turned OFF.......................................546
				Battery.............................................................546
				Tires and Wheels....................................................547
				Frame and Load Wheels...............................................547
				Safety Labels.......................................................548
				Overhead Guard......................................................548
				Forks Check.........................................................548
				Lift Chain Check....................................................549
				Mast Check..........................................................550
				Reach, Tilt, and Sideshift..........................................550
			Checks With Key Switch Turned ON........................................550
				Operation...........................................................550
				Hydraulic System....................................................551
				Dash Display........................................................551
				Lift System Operation...............................................552
				Multifunction Control Handle........................................553
				Brake...............................................................553
				Steering System.....................................................553
		Maintenance Procedures Every 500 Hours or 3 Months..........................554
			Master Drive Unit.......................................................554
			Hydraulic System........................................................554
			Hydraulic Filter Element Change.........................................556
			Caster Adjustment.......................................................556
				Elastomer Spring Type Adjustment....................................556
				Belleville Spring Type Adjustment...................................557
				Spring Pack Replacement.............................................559
					Remove Spring Assembly..........................................559
					Replace Spring Pack.............................................559
					Install Spring Assembly.........................................560
			Drive Tire Check........................................................560
			Lift System Operation...................................................560
				Forks...............................................................560
				Mast................................................................561
				Lift Chains.........................................................561
			Other Lubrication.......................................................561
		Maintenance Procedures Every 2000 Hours or Yearly...........................561
			Brakes..................................................................561
				Check...............................................................561
			Electric System.........................................................562
				Main Contactor......................................................562
					Inspect.........................................................562
			Hydraulic System........................................................563
				Drain...............................................................563
					Cylinder Identification.........................................564
				Fill................................................................565
					Main Lift Cylinders.............................................566
					Free-Lift Cylinders.............................................566
				Hydraulic Filter Change.............................................567
				Check Hydraulic Strainer............................................568
		Lift and Tilt System Leaks Check............................................568
			Lift System.............................................................568
			Tilt System.............................................................569
		Battery Maintenance.........................................................569
			How to Charge Battery...................................................569
			How to Change Battery...................................................570
		Tires and Wheels............................................................573
			Drive Tire..............................................................573
			How to Change Drive Tire................................................573
			Tandem Load Wheels......................................................574
			Caster Wheels...........................................................574
				Remove..............................................................574
				Install.............................................................575
		Preparation for Storage.....................................................576
			Short-Term Storage (1 to 6 months)......................................576
			Long-Term Storage (6 months or longer)..................................576
	tables..........................................................................529
		Table 1. Maintenance Schedule...............................................543
		Table 2. Fork Tip Alignment.................................................548
		Table 3. Hydraulic Tank Capacities..........................................555
		Table 4. Caster Specifications..............................................557
		Table 5. Upper Adjustment Gap Measurement...................................558
		Table 6. Free-Lift Cylinder Rod Widths......................................564
		Table 7. Battery Size Specifications........................................572
		Table 8. Tires and Wheels...................................................573
524233345-8000YRM1198-(05-2008)-US-EN...............................................579
	toc.............................................................................579
		Capacities and Specifications...............................................579
		Safety Precautions Maintenance and Repair...................................580
		Lubrication Specifications..................................................583
		Oil Capacities..............................................................583
		Hydraulic System............................................................584
		Lift Specifications.........................................................585
		Tire Sizes..................................................................590
		Torque Specifications.......................................................590
			Master Drive Unit.......................................................590
			Reach Carriage..........................................................590
			Mast....................................................................590
			Hydraulic System ( NDR030/035EA and NR030/040/045EA )...................591
			Hydraulic System ( NDR030DA and NR035/040DA )...........................591
			Steering System.........................................................591
			Load Wheels.............................................................591
		Fuses.......................................................................591
		Coil Resistance Values......................................................592
		Battery Specifications......................................................593
524233346-8000YRM1199-(02-2009)-US-EN...............................................597
	toc.............................................................................597
		Diagrams....................................................................597
		Safety Precautions Maintenance and Repair...................................598
524260263-2200YRM1240-(11-2008)-US-EN...............................................635
	toc.............................................................................635
		User Interface..............................................................635
		Safety Precautions Maintenance and Repair...................................636
		General.....................................................................639
			Description.............................................................639
			Dash Display Menu Access................................................639
		Menu Navigation.............................................................640
		Main Menu...................................................................640
		Diagnostics Menu............................................................640
			Static Diagnostics......................................................640
			Traction System.........................................................642
			Hydraulic System........................................................642
			Steer System............................................................643
			Error Log...............................................................644
		View Hourmeters.............................................................645
			Truck...................................................................645
			Traction................................................................645
			Pump....................................................................645
			Auxiliary...............................................................645
		Setup Menu..................................................................646
			Display Settings........................................................646
				Display Language....................................................646
				Year, Month, Date, Hour, Minute, and Second.........................646
		View Software Versions......................................................646
			Master Controller.......................................................646
			Display.................................................................647
			Traction Controller.....................................................647
			Hydraulic Controller....................................................647
			Control Handle..........................................................647
			Remote CAN Module ( NDR035EA, NR045EA, NDR030EA, NR035/040EA Onl........647
			Steer Controller........................................................647
			Caster Controller.......................................................647
			Aux Pump................................................................647
		Passwords Menu..............................................................648
			View Operator Log.......................................................648
			Add Password............................................................650
			Delete Password.........................................................651
			Edit Password...........................................................652
		Setup Shelf Height..........................................................653
		Learn Shelf Height..........................................................653
		Impact Sensor...............................................................654
			Functions...............................................................655
				Impact Action.......................................................655
				Impact Sound........................................................655
				Clear Impact........................................................655
				Hard Duration.......................................................655
				Hard Acceleration...................................................655
				Soft Duration.......................................................655
				Soft Acceleration...................................................656
				Impact Events.......................................................656
		Maintenance Reminder........................................................656
			Functions...............................................................656
				Maintenance Reminder................................................656
				Maintenance Interval................................................656
	tables..........................................................................635
		Table 1. Enter Password Screen..............................................639
		Table 2. Static Diagnostics Menu............................................641
		Table 3. Traction System Menu...............................................642
		Table 4. Hydraulic System Menu..............................................642
		Table 5. Steer System Menu..................................................643
		Table 6. Impact Sensor Data Display.........................................654
524260264-2200YRM1241-(11-2008)-US-EN...............................................659
	toc.............................................................................659
		User Interface..............................................................659
		Safety Precautions Maintenance and Repair...................................660
		General.....................................................................665
			Description.............................................................665
			Dash Display Menu Access................................................665
		Menu Navigation.............................................................666
		Main Menu...................................................................666
		Diagnostics Menu............................................................666
			Static Diagnostics......................................................666
			Traction System.........................................................668
			Hydraulic System........................................................668
			Steer System............................................................669
			General Truck...........................................................670
				Height Sensor.......................................................670
				Calibrate Fork Tare Down............................................670
				Calibrate Fork Tare Up..............................................670
				Calibrate Cushion Inpoint ( NDR035EA, NR045EA, NDR030EA, NR035/0....671
				Calibrate Cushion Outpoint ( NDR035EA, NR045EA, NDR030EA, NR035/....671
				Calibrate Mast Slowdown.............................................671
			Error Log...............................................................671
		View Hourmeters.............................................................672
			Truck...................................................................672
			Traction................................................................672
			Pump....................................................................672
			Auxiliary...............................................................672
		Setup Menu..................................................................673
			Lift Settings...........................................................674
				Lift Maximum Speed ( NDR035EA, NR045EA, NDR030EA, NR035/040EA ).....674
				Lower Maximum Speed ( NDR035EA, NR045EA, NDR030EA, NR035/040EA )....674
				Lift Acceleration...................................................674
			Auxiliary Settings......................................................675
				Fast Extend Speed...................................................675
				Slow Extend Speed...................................................675
				Fast Retract Speed..................................................675
				Slow Retract Speed..................................................676
				Tilt Up Speed.......................................................676
				Tilt Down Speed.....................................................676
				Sideshift Speed.....................................................676
				Reach Cushioning....................................................676
			Steer Settings..........................................................676
				Steer Mode..........................................................677
				Steer Effort........................................................677
				Steer Ratio.........................................................677
			Display Settings........................................................677
				Display Language....................................................677
				Year, Month, Date, Hour, Minute, and Second.........................677
			Truck Settings..........................................................678
				Serial Number.......................................................678
				Voltage.............................................................678
				Capacity Lbs........................................................678
				Battery Type........................................................678
				BDI Adjust Calibration..............................................678
				Extended Shift......................................................679
				Shelf Height Selection..............................................679
				Load Weight Option ( NDR035EA, NR045EA, NDR030EA, NR035/040EA ).....679
				Lift Limit Without Override ( NDR035EA, NR045EA, NDR030EA, NR035....679
				Lift Limit With Override............................................679
				Audible Alarm.......................................................679
				Visible Alarm Option................................................679
				Fork Height Display.................................................680
				Auto Tilt Option....................................................680
				Laser Option........................................................680
				Carry Level Option..................................................680
				Slow Extended.......................................................680
				Simultaneous Hydraulics.............................................680
				Password Option.....................................................680
				Shutdown Timeout....................................................680
				Truck Inspection....................................................680
			Traction Settings.......................................................680
				Rabbit Speed........................................................680
				Rabbit Acceleration.................................................681
				High Speed..........................................................681
				High Acceleration...................................................681
				Mid Speed...........................................................681
				Mid Acceleration....................................................681
				Turtle Speed........................................................681
				Turtle Acceleration.................................................681
				Neutral Braking.....................................................682
				Plug Braking........................................................682
		View Software Versions......................................................682
			Master Controller.......................................................682
			Display.................................................................682
			Traction Controller.....................................................682
			Hydraulic Controller....................................................682
			Control Handle..........................................................683
			Remote CAN Module ( NDR035EA, NR045EA, NDR030EA, NR035/040EA )..........683
			Steer Controller........................................................683
			Caster Controller.......................................................683
			Aux Pump................................................................683
		Passwords Menu..............................................................683
			Functions...............................................................684
				View Operator Log...................................................684
				Add Password........................................................684
				Delete Password.....................................................686
				Edit Password.......................................................686
		Setup Shelf Height..........................................................687
		Learn Shelf Height..........................................................688
		Impact Sensor...............................................................688
			Functions...............................................................690
				Impact Action.......................................................690
				Impact Sound........................................................690
				Clear Impact........................................................690
				Hard Duration.......................................................690
				Hard Acceleration...................................................690
				Soft Duration.......................................................690
				Soft Acceleration...................................................690
				Impact Events.......................................................690
		Maintenance Reminder........................................................691
			Functions...............................................................691
				Maintenance Reminder................................................691
				Maintenance Interval................................................691
	tables..........................................................................659
		Table 1. Enter Password Screen..............................................665
		Table 2. Static Diagnostics Menu............................................667
		Table 3. Traction System Menu...............................................668
		Table 4. Hydraulic System Menu..............................................668
		Table 5. Steer System Menu..................................................669
		Table 6. General Truck Menu.................................................670
		Table 7. Impact Sensor Data Display.........................................689
524287793-1900YRM1307-(11-2006)-US-EN...............................................695
	toc.............................................................................695
		Hydraulic System............................................................695
		Safety Precautions Maintenance and Repair...................................696
		General.....................................................................699
			Discharging the Capacitors..............................................701
		Description.................................................................701
		Control Handle..............................................................701
			Sidestance Control Handle...............................................701
			Fore/Aft Stance.........................................................702
		Maintenance.................................................................704
			Oil Level and Leaks.....................................................704
			Operation...............................................................704
			Oil Change..............................................................704
				Drain...............................................................704
				Cylinder Identification.............................................706
				Fill................................................................707
					Main Lift Cylinders.............................................708
					Free-Lift Cylinders.............................................708
			Breather Cap............................................................709
				Inspect.............................................................709
			Oil Filter..............................................................709
				Change..............................................................709
			Oil Strainer............................................................710
				Check...............................................................710
		Hydraulic System............................................................710
			General.................................................................710
				Cleaning............................................................711
				Noise Levels........................................................711
			Hoses...................................................................711
			Fittings................................................................712
		Lift Pump and Motor.........................................................712
			Complete Unit...........................................................712
				Remove..............................................................712
				Install.............................................................713
			Lift Pump...............................................................713
				Remove..............................................................713
				Disassemble.........................................................714
				Assemble............................................................715
				Install.............................................................716
		Main Control Valve..........................................................716
			Description.............................................................716
				Check...............................................................716
					Tilt Valve Test.................................................716
				Remove..............................................................717
				Disassemble.........................................................717
				Clean...............................................................718
				Assemble............................................................718
				Install.............................................................718
			Manual Lowering.........................................................719
		Auxiliary Hydraulics........................................................720
			Front Selector Valve....................................................720
			Rear Selector Valve.....................................................720
		Hydraulic Tank..............................................................722
			Remove..................................................................722
			Disassemble.............................................................723
				Breather Assembly...................................................723
				Filter Assembly.....................................................724
				Low Oil Indicator Switch............................................724
				Tank Fittings.......................................................726
			Clean and Inspect.......................................................726
			Assemble................................................................726
				Breather Assembly...................................................726
				Filter Assembly.....................................................726
				Low Oil Indicator Switch............................................726
				Tank Fittings.......................................................726
			Install.................................................................727
		Specifications..............................................................727
		Troubleshooting.............................................................728
	tables..........................................................................695
		Table 1. Cylinder Identification............................................706
524287794-2200YRM1308-(11-2008)-US-EN...............................................733
	toc.............................................................................733
		AC Motor Controllers/Display Panel..........................................733
		Safety Precautions Maintenance and Repair...................................734
		Description.................................................................737
			General.................................................................737
				AC Motors...........................................................737
				Motor Controllers...................................................737
				Master Controller...................................................738
				Dash Display........................................................738
				Controller Area Network Bus (CANbus)................................738
		AC Transistor Motor Controller Replacement..................................739
			General.................................................................739
			General Maintenance Instructions........................................741
				Special Precautions.................................................741
			Fuses...................................................................742
			Fan.....................................................................742
			Contactors..............................................................742
				Repair..............................................................742
		Master Controller Checks and Adjustments....................................743
		Function Settings...........................................................744
			General.................................................................744
		Troubleshooting.............................................................746
			General.................................................................746
			Controller Status Light Emitting Diodes (LEDs)..........................747
				Master Controller...................................................747
				AC Motor Controllers................................................747
			Operator Status Messages................................................750
			Status Codes............................................................754
			Checking the Motor Controller...........................................809
		Display Panel...............................................................809
			General.................................................................809
				Premium Display Panel...............................................809
				Standard Display Panel..............................................810
		Standard Display Functions and Features.....................................810
			Key-On Initialization...................................................810
			Passwords...............................................................811
			Performance Modes.......................................................811
			Battery Discharge Indicator (BDI).......................................811
			Hourmeters..............................................................812
		Standard Dash Display Service Menu Navigation...............................812
			General.................................................................812
			Moving Through Menu Selections..........................................812
			Editing and Adding Information..........................................812
			Access to Service Functions.............................................813
			Service Functions.......................................................813
		Premium Display Functions and Features......................................815
			Key-On Initialization...................................................815
			Passwords...............................................................815
			Operator Checklist Function.............................................815
			Performance Modes.......................................................815
			Battery Discharge Indicator.............................................816
			Hourmeters..............................................................816
			Shelf Height Selector...................................................816
		Premium Dash Display Service Menu Navigation................................817
			General.................................................................817
			Moving Through Menu Selections..........................................817
			Access to Service Functions.............................................818
			Service Functions.......................................................818
		Connector Pin-Outs..........................................................820
		System Logic Diagram........................................................827
	tables..........................................................................733
		Table 1. Factory Parameter Defaults.........................................744
		Table 2. Traction Parameter Defaults........................................745
		Table 3. List of Operator Warning Messages..................................750
		Table 4. List of Fault Messages.............................................755
		Table 5. Password Prompt Screen.............................................811
		Table 6. Password Prompt Screen.............................................812
		Table 7. Password Prompt Screen.............................................813
		Table 8. Password Prompt Screen.............................................815
		Table 9. Password Screen....................................................815
		Table 10. Password Prompt Screen............................................817
		Table 11. Password Prompt Screen............................................818

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