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Yale Forklift A295 (NR035-040DA; NDR030DA) Service Manual – PDF DOWNLOAD
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Description
Yale Forklift A295 (NR035-040DA; NDR030DA) Service Manual – PDF DOWNLOAD
FILE DETAILS:
Yale Forklift A295 (NR035-040DA; NDR030DA) Service Manual – PDF DOWNLOAD
Language : English
Pages : 874
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Yale Forklift A295 (NR035-040DA; NDR030DA) Service Manual – PDF DOWNLOAD
General 5
Threaded Fasteners 5
Nomenclature, Threads 5
Strength Identification 6
Cotter (Split) Pins 7
Fastener Torque Tables 12
Conversion Table 14
General 27
Battery Type 27
Lead-Acid Batteries 27
Lithium-Ion Batteries 28
Specific Gravity 28
Chemical Reaction in a Cell 28
Electrical Terms 30
Battery Selection 31
Battery Voltage 32
Battery as a Counterweight 32
Battery Ratings 32
Kilowatt-Hours 32
Battery Maintenance 33
Safety Procedures 33
Maintenance Records 33
New Battery 33
Cleaning Battery 34
Adding Water to Battery 36
Hydrometer 36
Battery Temperature 37
Charging Battery 38
Types of Battery Charges 39
Methods of Charging 40
Troubleshooting Charger 41
Knowing When Battery Is Fully Charged 41
Where to Charge Batteries 41
Equipment Needed 41
Battery Connectors 42
Battery Care 42
Troubleshooting 44
General 53
Battery Type 53
Lead-Acid Batteries 53
Lithium-Ion Batteries 54
Specific Gravity 54
Chemical Reaction in a Cell 54
Electrical Terms 56
Battery Selection 56
Battery Voltage 57
Battery as a Counterweight 58
Battery Ratings 58
Kilowatt-Hours 58
Battery Maintenance 58
Safety Procedures 58
Maintenance Records 59
New Battery 59
Cleaning Battery 59
Adding Water to Battery 61
Hydrometer 62
Battery Temperature 63
Charging Battery 64
Types of Battery Charges 64
Methods of Charging 66
Troubleshooting Charger 66
Knowing When Battery Is Fully Charged 67
Where to Charge Batteries 67
Equipment Needed 67
Battery Connectors 68
Battery Care 68
Troubleshooting 70
General 79
Description 79
Lowering Control Valve 80
Main Cylinder Repair 81
Disassemble 82
Assemble 83
Free-Lift Cylinder Repair 84
Disassemble 84
Assemble 84
Troubleshooting 86
toc 89
Master Drive Unit 89
Safety Precautions Maintenance and Repair 90
HFK400 Master Drive Unit 93
General 93
Description 93
Drive Unit Maintenance and Repair 94
Remove 94
Install 95
Disassemble 95
Assemble 99
Troubleshooting 107
GK Master Drive Unit 109
General 109
Description 109
Maintenance 110
Changing the Oil 110
Traction Motor and Drive Unit Splines 110
Remove 110
Assemble 111
Mounting Electric Motor 112
Pivoted Connection – Geared Steering 112
Disassemble 113
Install 113
Troubleshooting 114
tables 89
Table 1 Tooth Contact Pattern 104
toc 117
Troubleshooting and Adjustments Using the AC Controls Program (E 117
Safety Precautions Maintenance and Repair 118
General 121
Computer Requirements 121
Software, Install 121
Language Selection 121
Demo Mode 122
Connect PC to Lift Truck 126
Starting AC Controls Program 128
Lift Truck Control Setup 133
Change Lift Truck Serial Number or Hourmeter 133
Setting Factory Default Values or Changing Lift Truck Parameters 134
Create New Custom Lift Truck Configuration 140
Lift Truck Configuration Properties 143
Import New Lift Truck Configuration From Disk 146
Delete Custom Lift Truck Configuration or Password File 148
Dash Display 151
Custom Display Languages 151
Download Display Language 153
Clear Operator Log 153
Password Functions 156
Enable/Disable Password and Lift Truck Inspection Functions 156
Truck Inspection Checklist 156
Password 156
Password Properties 156
Create New Password File 161
Download Passwords 162
Upload Passwords 164
Reports Menu 166
Devices Report 166
Custom Report 166
Password Report 166
Operator Report 173
Current Settings Report 176
Status Code Report 180
Status Codes Log 183
Troubleshooting 185
Diagnostics 185
Help Menu 188
General 188
Contents 188
Technical Support 188
About Electric Truck AC Controls Program 188
toc 195
Steering System 195
Safety Precautions Maintenance and Repair 196
General 199
Discharging the Capacitors 200
Raising the Lift Truck 201
How to Raise the Drive Tire End 201
How to Raise the Entire Lift Truck 202
Description 202
Steering Handle Assembly 205
Fixed Handle 205
Description 205
Remove 205
Disassemble 207
Assemble 209
Install 209
Adjustable Handle 210
Description 210
Remove 210
Disassemble 210
Assemble 214
Install 214
Steering Controller 215
Description 215
Remove 215
Disassemble 215
Assemble 216
Install 216
Steering Proximity Switch 216
Replace 216
Steering Motor 217
Description 217
Remove 217
Disassemble 218
Assemble 218
Install 218
Caster Assembly – General 219
Caster Adjustment 219
Elastomer Spring Type Adjustment 219
Belleville Spring Type Adjustment 220
Spring Pack Replacement 222
Remove Spring Assembly 222
Replace Spring Pack 223
Install Spring Assembly 223
Caster Wheels 224
Remove 224
Install 224
Caster Wheel Assembly (Nonsteered) 225
Description 225
Remove 226
Disassemble 227
Upper and Lower Support Housings 227
Spring Assembly From Lower Support Assembly 227
Caster Spindle From Lower Support 227
Caster Wheels 228
Lower Support Housing 228
Upper Support Housing 229
Assemble 230
Upper Support Housing 230
Lower Support Housing 231
Caster Wheels 231
Caster Spindle to Lower Support 232
Spring Assembly to Lower Support 232
Upper and Lower Support Housings 232
Install 232
Caster Assembly (Steered) 234
Description 234
Remove 234
Disassemble 236
Upper and Lower Support 236
Spring Assembly From Lower Support Housing 236
Caster Spindle From Lower Support 236
Caster Wheels 237
Lower Support Housing 238
Upper Support Housing 239
Caster Steering Motor 239
Assemble 240
Caster Steering Motor 240
Upper Support Housing 240
Lower Support Housing 241
Caster Wheels 242
Caster Spindle to Lower Support 242
Spring Assembly to Lower Support 243
Upper and Lower Support Housings 243
Install 244
Troubleshooting 245
tables 195
Table 1 Caster Specifications 220
Table 2 Upper Adjustment Gap Measurement 222
toc 249
Frame 249
Safety Precautions Maintenance and Repair 250
General 253
Description 253
Repairs – General 254
Covers, Panels, and Plates 254
Front Frame Panel (Left and Right) 254
Operator Compartment Cover 255
Drive Unit Compartment Door 255
Door Pad 255
Operator Back Pad 255
Side-Stance Models 255
Forward-Stance Models 255
Operator Front Pad 256
Caster Wheel Cover 256
Load Wheels 256
Remove 256
Install 256
Overhead Guard Replacement 257
Remove 261
Install 261
Front Lights 261
Bulb Replacement 261
Assembly Replacement 262
Rear Work and Caution Light 263
Caution Light 263
Painting Instructions 264
Safety Labels Replacement 265
toc 271
AC Motor Repair 271
Safety Precautions Maintenance and Repair 272
General 275
Traction Motor Repair 276
Disassemble 276
Inspect 277
Assemble 277
Drive End Bearing, Replace 278
Hydraulic Motor Repair 279
Disassemble 279
Inspect 281
Assemble 282
Troubleshooting 283
tables 271
Table 1 Traction Motor Windings 277
Table 2 Hydraulic Motor Windings 282
Introduction 291
General 291
Discharging the Capacitors 291
Electric Brake 292
Air Gap 293
Remove 294
Install 295
Troubleshooting 296
toc 301
Electrical System 301
Safety Precautions Maintenance and Repair 302
General 307
Discharging the Capacitors 308
Static Strap 308
Inspect 308
Replace 308
Battery Connection 309
Inspect 309
Replacing Cables 309
Key Switch 310
Replace 310
Contactors 312
Function 312
Testing 313
Remove 313
Install 314
EE Contactors 314
Motor Controllers 315
Functions 315
Master Controller 315
Steering Motor Controller 315
Traction Motor Controller 315
Lift Motor Controller 315
Steer Caster Controller (Optional) 315
Replace 315
Traction and Lift Motor Controllers 316
Master Controller 316
Steering Controller 316
Steer Caster Controller (Option) 317
Integrated Fuse Board (IFB) 317
Fuses 318
Replace 318
Power Disconnect Switch 319
Replace 319
Side-Stance Controls 320
Multifunction Control Handle 320
Remove 321
Disassemble 321
Assemble 323
Install 323
Forward-Stance Controls 324
Control Handle Functions 324
Repair 324
Aft Travel Control Handle Option 326
Repair 327
Steering Handle 328
Steering Unit Repair 328
Foot Switches 332
Brake Switch 332
Operator Sensing 332
Repair 332
Dash Display Assembly 333
Description 333
Remove 334
Test 335
Install 335
Horn 336
Audible Alarm 336
Light Assemblies 337
Front Lights 337
Bulb Replacement 337
Assembly Replacement 337
Rear Work and Caution Light 338
Rear Work Light 338
Caution Light 338
Light Switches 339
Cooling Fans 341
Electrical Compartment Fans 341
Replace 341
Operator Fan 343
Repair 343
Impact Sensor 345
Remove 345
Install 345
Height Proximity Switch 346
Test 346
Remove 346
Install 347
Adjust 347
Load Transport Proximity Switch 348
Replace 348
Adjust 349
Fork Height Sensor Option 349
Remove 349
Encoder Assembly 349
Timing Belt 350
Install 351
Encoder Assembly 351
Timing Belt 352
Reach Position Sensor 352
Remove 352
Install 354
Retract Sensor 355
Remove 355
Install 355
Tilt Leveling 357
Remove 357
Install 357
Laser Option 358
Remove 358
Install 358
Camera Option 359
Remove 359
Install 359
Wiring Harness 359
toc 367
User Interface 367
Safety Precautions Maintenance and Repair 368
General 371
Description 371
Dash Display Menu Access 371
Menu Navigation 372
Standard Display 372
Main Menu 372
Diagnostics Menu 373
Static Diagnostics 373
Traction System 377
Hydraulic System 378
Steer System 381
Error Log 382
View Hourmeters 382
View Software Versions 382
Master Controller 382
Display 383
Traction Controller 383
Hydraulic Controller 384
Control Handle 384
Remote CAN Module ( NDR035EA, NR045EA, NDR030EA, NR035/040EA ) 385
Steer Controller 385
Caster Controller 386
Aux Pump ( NDR035EA, NR045EA, NDR030EA, NR035/040EA ) 386
Impact Sensor 386
Functions 388
Impact Action 388
Impact Sound 388
Clear Impact 388
Hard Duration 388
Hard Acceleration 388
Soft Duration 388
Soft Acceleration 389
Impact Events 389
Passwords Menu 389
Add Password 390
Delete Password 391
Edit Password 392
tables 367
Table 1 Static Diagnostics Menu 373
Table 2 Traction System Diagnostics Menu 377
Table 3 Hydraulic System Diagnostics Menu 378
Table 4 Steering System Diagnostics Menu 381
Table 5 Error Log 382
Table 6 Master Controller Software Version 382
Table 7 Display Software Version 383
Table 8 Traction Controller Software Version 383
Table 9 Hydraulic Controller Software Version 384
Table 10 Control Handle Software Version 384
Table 11 Remote CAN Module Software Version 385
Table 12 Steer Controller Software Version 385
Table 13 Caster Controller Software Version 386
Table 14 Aux Pump Controller Software Version 386
Table 15 Impact Sensor Data Display 387
toc 395
User Interface 395
Safety Precautions Maintenance and Repair 396
General 399
Description 399
Dash Display Menu Access 399
Menu Navigation 400
Standard Display 400
Main Menu 400
Diagnostics Menu 400
Static Diagnostics 400
Traction System 404
Hydraulic System 405
Steer System 408
General Truck 409
Error Log 410
View Hourmeters 410
Truck Hours 410
Traction Hours 411
Pump Hours 411
Auxiliary Hours 412
Setup Menu 412
Lift Settings 412
Lift Maximum Speed ( NDR035EA, NR045EA, NDR030EA, NR035/040EA ) 412
Lower Maximum Speed ( NDR035EA, NR045EA, NDR030EA, NR035/040EA ) 413
Auxiliary Settings 413
Fast Extend Speed 413
Slow Extend Speed 414
Fast Retract Speed 414
Slow Retract Speed 415
Tilt Up Speed 415
Tilt Down Speed 416
Sideshift Speed 416
Reach Cushioning 417
Steer Settings 417
Steer Mode 417
Steer Effort 418
Steer Ratio 418
Truck Settings 419
Truck Serial Number 419
Truck Voltage 419
Truck Capacity 420
Battery Type 420
BDI Adjust 421
Extended Shift 421
Lift Limit Without Override ( NDR035EA, NR045EA, NDR030EA, NR035 422
Lift Limit With Override ( NDR035EA, NR045EA, NDR030EA, NR035/04 422
Audible Alarm 423
Visible Alarm 424
Autotilt Option 424
Laser Option 425
Carry Level Option 425
Slow Extended 426
Simultaneous Hydraulics 426
Password Option 427
Shutdown Timeout 427
Traction Settings 428
Rabbit Speed 428
Rabbit Acceleration 428
High Speed 429
High Acceleration 429
Mid Speed 430
Mid Acceleration 430
Turtle Speed 431
Turtle Acceleration 431
Neutral Braking 432
Plug Braking 432
View Software Versions 433
Master Controller 433
Display 433
Traction Controller 434
Hydraulic Controller 434
Control Handle 435
Remote CAN Module ( NDR035EA, NR045EA, NDR030EA, NR035/040EA ) 435
Steer Controller 436
Caster Controller 436
Aux Pump ( NDR035EA, NR045EA, NDR030EA, NR035/040EA ) 437
Impact Sensor 438
Functions 438
Functions 439
Impact Action 439
Impact Sound 439
Clear Impact 439
Hard Duration 439
Hard Acceleration 439
Soft Duration 439
Sort Acceleration 439
Impact Events 439
Password Menu 440
Add Password 441
Delete Password 442
Edit Password 443
tables 395
Table 1 Password Screen 399
Table 2 Static Diagnostics Menu 401
Table 3 Traction System Diagnostics Menu 404
Table 4 Hydraulic System Diagnostics Menu 405
Table 5 Steering System Diagnostics Menu 408
Table 6 General Truck Diagnostics Menu 409
Table 7 Error Log 410
Table 8 Truck Hours 410
Table 9 Traction Hours 411
Table 10 Pump Hours 411
Table 11 Auxiliary Hours 412
Table 12 Lift Maximum Speed Menu 412
Table 13 Lower Maximum Speed Menu 413
Table 14 Fast Extend Speed Menu 413
Table 15 Slow Extend Speed Menu 414
Table 16 Fast Retract Speed Menu 414
Table 17 Slow Retract Speed Menu 415
Table 18 Tilt Up Speed Menu 415
Table 19 Tilt Down Speed Menu 416
Table 20 Sideshift Speed Menu 416
Table 21 Cushioning Speed Menu 417
Table 22 Steer Mode Menu 417
Table 23 Steer Effort Menu 418
Table 24 Steer Ratio Menu 418
Table 25 Truck Serial Number Menu 419
Table 26 Truck Voltage Menu 419
Table 27 Truck Capacity Menu 420
Table 28 Truck Type Menu 420
Table 29 BDI Adjust Menu 421
Table 30 Extended Shift Menu 421
Table 31 Lift Limit Without Override 422
Table 32 Lift Limit With Override 422
Table 33 Audible Alarm Menu 423
Table 34 Visible Alarm Menu 424
Table 35 Autotilt Option Menu 424
Table 36 Laser Option 425
Table 37 Carry Level Option Menu 425
Table 38 Restore Defaults Menu 426
Table 39 Simultaneous Hydraulics Menu 426
Table 40 Password Option Menu 427
Table 41 Shutdown Timeout Menu 427
Table 42 Rabbit Speed Menu 428
Table 43 Rabbit Acceleration Menu 428
Table 44 High Speed Menu 429
Table 45 High Acceleration Menu 429
Table 46 Mid Speed Menu 430
Table 47 Mid Acceleration Menu 430
Table 48 Turtle Speed Menu 431
Table 49 Turtle Acceleration Menu 431
Table 50 Neutral Braking Menu 432
Table 51 Plug Braking Menu 432
Table 52 Master Controller Software Version 433
Table 53 Display Software Version 433
Table 54 Traction Controller Software Version 434
Table 55 Hydraulic Controller Software Version 434
Table 56 Control Handle Software Version 435
Table 57 Remote CAN Module Software Version 435
Table 58 Steer Controller Software Version 436
Table 59 Caster Controller Software Version 436
Table 60 Aux Pump Controller Software Version 437
Table 61 Impact Sensor Data Display 438
General 451
Safety Procedures When Working Near Mast 452
Mast Weldments 454
Reach Carriage Assembly 454
Three-Stage Mast 456
Description 456
Operation 457
General 465
Safety Procedures When Working Near Mast 465
Description 466
Repair – General 468
Load Backrest 468
Remove 468
Install 468
Forks 469
Replacement 469
Remove 469
Install 469
Reach Carriage Assembly 470
Remove 470
Inspect 471
Install 472
Reach Carriage Assembly Repair 472
Load Rollers Repair 473
Side Rollers Repair (6 9 Mast Only) (NDR030DA and NR035/040DA) 474
Reach Assembly Front Frame 475
Remove 475
Disassemble (With Sideshift) 476
Disassemble (Without Sideshift) 478
Clean and Inspect 479
Assemble (With Sideshift) 479
Assemble (Without Sideshift) 479
Install 480
Single-Reach Scissor Arms 480
Remove and Disassemble 480
Clean and Inspect 484
Assemble and Install 484
Double-Reach Scissor Arms 486
Disassemble 486
Clean and Inspect 490
Assemble 490
Rear Frame Assembly 493
Remove 493
Disassemble 495
Clean and Inspect 496
Assemble 496
Install 496
Reach Cylinders 498
Remove 498
Disassemble 499
Clean and Inspect 500
Assemble 500
Install 501
Tilt Cylinder 501
Remove 501
Clean, Inspect, and Repair 502
Install 503
Sideshift Cylinder 503
Repair 503
Front Selector Valve 504
Rear Selector Valve 505
Reach Assembly Adjustments 505
Check Adjustment 506
Adjust Side Rollers and Load Rollers 507
Adjust Reach Cylinders 508
Lift Chains 509
Inspect 509
Clean and Lubricate 510
Adjust Main-Lift Chains 510
Adjust Free-Lift Chains 510
Specifications 511
Troubleshooting 514
toc 519
Periodic Maintenance 519
Safety Precautions Maintenance and Repair 520
General 523
Removing Covers 523
Front Frame Panel (Left and Right) 523
Operator Compartment Cover 524
Drive Unit Compartment Door 525
Caster Wheel Cover 525
Discharging the Capacitors 525
How to Move Disabled Truck 526
How to Tow Lift Truck 526
How to Put Lift Truck on Blocks 527
How to Raise Load Wheels 527
How to Raise the Drive Tire End 528
How to Raise the Entire Lift Truck 528
Manual Lowering Valve 528
NDR030/035EA and NR030/040/045EA 528
NDR030DA and NR035/040DA 529
Transporting 530
Loading 530
Unloading 530
Preparation for Use 531
Preparation After Shipment 531
Preparation After Storage 531
Safety Procedures When Working Near Mast 531
Maintenance Schedule 532
Maintenance Procedures Every 8 Hours or Daily 537
Checks With Key Switch Turned OFF 537
Battery 537
Tires and Wheels 538
Frame and Load Wheels 538
Safety Labels 538
Overhead Guard 539
Forks Check 539
Lift Chain Check 540
Mast Check 541
Reach, Tilt, and Sideshift 541
Checks With Key Switch Turned ON 541
Operation 541
Hydraulic System 542
Dash Display 542
Lift System Operation 543
Multifunction Control Handle 544
Brake 544
Steering System 544
Maintenance Procedures Every 500 Hours or 3 Months 545
Master Drive Unit 545
Hydraulic System 545
Hydraulic Filter Element Change 547
Caster Adjustment 547
Elastomer Spring Type Adjustment 547
Belleville Spring Type Adjustment 549
Spring Pack Replacement 550
Remove Spring Assembly 550
Replace Spring Pack 551
Install Spring Assembly 551
Drive Tire Check 551
Lift System Operation 552
Forks 552
Mast 552
Lift Chains 552
Other Lubrication 552
Maintenance Procedures Every 2000 Hours or Yearly 553
Brakes 553
Check 553
Electric System 553
Main Contactor 553
Inspect 553
Master Drive Unit 554
Hydraulic System 554
Drain 554
Cylinder Identification 555
Fill 557
Main Lift Cylinders 557
Free-Lift Cylinders 558
Hydraulic Filter Change 559
Check Hydraulic Strainer 559
Lift and Tilt System Leaks Check 560
Lift System 560
Tilt System 560
Battery Maintenance 561
How to Charge Battery 561
How to Change Battery 562
Tires and Wheels 564
Drive Tire 564
How to Change Drive Tire 565
Tandem Load Wheels 566
Caster Wheels 566
Remove 566
Install 567
Preparation for Storage 568
Short-Term Storage (1 to 6 months) 568
Long-Term Storage (6 months or longer) 568
tables 519
Table 1 Maintenance Schedule 533
Table 2 Fork Tip Alignment 539
Table 3 Hydraulic Tank Capacities 546
Table 4 Caster Specifications 548
Table 5 Upper Adjustment Gap Measurement 550
Table 6 Free-Lift Cylinder Rod Widths 557
Table 7 Battery Size Specifications 564
Table 8 Tires and Wheels 565
toc 571
Capacities and Specifications 571
Safety Precautions Maintenance and Repair 572
Lubrication Specifications 575
Oil Capacities 575
Hydraulic System 576
Lift Specifications 577
Tire Sizes 582
Torque Specifications 582
Master Drive Unit 582
Reach Carriage 582
Mast 582
Hydraulic System ( NDR030/035EA and NR030/040/045EA ) 583
Hydraulic System ( NDR030DA and NR035/040DA ) 583
Steering System 583
Load Wheels 583
Fuses 583
Coil Resistance Values 584
Battery Specifications 585
toc 653
User Interface 653
Safety Precautions Maintenance and Repair 654
General 657
Description 657
Dash Display Menu Access 657
Menu Navigation 658
Main Menu 658
Diagnostics Menu 658
Static Diagnostics 658
Traction System 660
Hydraulic System 660
Steer System 661
Error Log 662
View Hourmeters 663
Truck 663
Traction 663
Pump 663
Auxiliary 663
Setup Menu 664
Display Settings 664
Display Language 664
Year, Month, Date, Hour, Minute, and Second 664
View Software Versions 664
Master Controller 664
Display 665
Traction Controller 665
Hydraulic Controller 665
Control Handle 665
Remote CAN Module ( NDR035EA, NR045EA, NDR030EA, NR035/040EA Onl 665
Steer Controller 665
Caster Controller 665
Aux Pump 665
Passwords Menu 666
View Operator Log 666
Add Password 668
Delete Password 669
Edit Password 670
Setup Shelf Height 671
Learn Shelf Height 671
Impact Sensor 672
Functions 673
Impact Action 673
Impact Sound 673
Clear Impact 673
Hard Duration 673
Hard Acceleration 673
Soft Duration 673
Soft Acceleration 674
Impact Events 674
Maintenance Reminder 674
Functions 674
Maintenance Reminder 674
Maintenance Interval 674
tables 653
Table 1 Enter Password Screen 657
Table 2 Static Diagnostics Menu 659
Table 3 Traction System Menu 660
Table 4 Hydraulic System Menu 660
Table 5 Steer System Menu 661
Table 6 Impact Sensor Data Display 672
toc 677
User Interface 677
Safety Precautions Maintenance and Repair 678
General 683
Description 683
Dash Display Menu Access 683
Menu Navigation 684
Main Menu 684
Diagnostics Menu 684
Static Diagnostics 684
Traction System 686
Hydraulic System 686
Steer System 687
General Truck 688
Height Sensor 688
Calibrate Fork Tare Down 688
Calibrate Fork Tare Up 688
Calibrate Cushion Inpoint ( NDR035EA, NR045EA, NDR030EA, NR035/0 689
Calibrate Cushion Outpoint ( NDR035EA, NR045EA, NDR030EA, NR035/ 689
Calibrate Mast Slowdown 689
Error Log 689
View Hourmeters 690
Truck 690
Traction 690
Pump 690
Auxiliary 690
Setup Menu 691
Lift Settings 692
Lift Maximum Speed ( NDR035EA, NR045EA, NDR030EA, NR035/040EA ) 692
Lower Maximum Speed ( NDR035EA, NR045EA, NDR030EA, NR035/040EA ) 692
Lift Acceleration 692
Auxiliary Settings 693
Fast Extend Speed 693
Slow Extend Speed 693
Fast Retract Speed 693
Slow Retract Speed 694
Tilt Up Speed 694
Tilt Down Speed 694
Sideshift Speed 694
Reach Cushioning 694
Steer Settings 694
Steer Mode 695
Steer Effort 695
Steer Ratio 695
Display Settings 695
Display Language 695
Year, Month, Date, Hour, Minute, and Second 695
Truck Settings 696
Serial Number 696
Voltage 696
Capacity Lbs 696
Battery Type 696
BDI Adjust Calibration 696
Extended Shift 697
Shelf Height Selection 697
Load Weight Option ( NDR035EA, NR045EA, NDR030EA, NR035/040EA ) 697
Lift Limit Without Override ( NDR035EA, NR045EA, NDR030EA, NR035 697
Lift Limit With Override 697
Audible Alarm 697
Visible Alarm Option 697
Fork Height Display 698
Auto Tilt Option 698
Laser Option 698
Carry Level Option 698
Slow Extended 698
Simultaneous Hydraulics 698
Password Option 698
Shutdown Timeout 698
Truck Inspection 698
Traction Settings 698
Rabbit Speed 698
Rabbit Acceleration 699
High Speed 699
High Acceleration 699
Mid Speed 699
Mid Acceleration 699
Turtle Speed 699
Turtle Acceleration 699
Neutral Braking 700
Plug Braking 700
View Software Versions 700
Master Controller 700
Display 700
Traction Controller 700
Hydraulic Controller 700
Control Handle 701
Remote CAN Module ( NDR035EA, NR045EA, NDR030EA, NR035/040EA ) 701
Steer Controller 701
Caster Controller 701
Aux Pump 701
Passwords Menu 701
Functions 702
View Operator Log 702
Add Password 702
Delete Password 704
Edit Password 704
Setup Shelf Height 705
Learn Shelf Height 706
Impact Sensor 706
Functions 708
Impact Action 708
Impact Sound 708
Clear Impact 708
Hard Duration 708
Hard Acceleration 708
Soft Duration 708
Soft Acceleration 708
Impact Events 708
Maintenance Reminder 709
Functions 709
Maintenance Reminder 709
Maintenance Interval 709
tables 677
Table 1 Enter Password Screen 683
Table 2 Static Diagnostics Menu 685
Table 3 Traction System Menu 686
Table 4 Hydraulic System Menu 686
Table 5 Steer System Menu 687
Table 6 General Truck Menu 688
Table 7 Impact Sensor Data Display 707
General 717
Discharging the Capacitors 720
Description 720
Control Handle (A295) 720
Sidestance Control Handle
721
Fore/Aft Stance 722
Control Handle (B295) 722
Sidestance Control Handle 723
Fore/Aft Stance 724
Maintenance 724
Oil Level and Leaks 725
Operation 725
Oil Change 725
Drain 725
Cylinder Identification 727
Fill 728
Main Lift Cylinders 729
Free-Lift Cylinders 729
Breather Cap 730
Inspect 730
Oil Filter 730
Change 730
Oil Strainer 731
Check 731
Hydraulic System 732
General 732
Cleaning 732
Noise Levels 732
Hoses 733
Fittings 735
Lift Pump and Motor 735
Complete Unit 735
Remove 735
Install 736
Lift Pump 737
Remove 737
Disassemble 738
Assemble 738
Install 739
Main Control Valve 740
Description 740
Check 740
Tilt Valve Test 740
Remove 740
Disassemble 741
Clean 741
Assemble 742
Install 742
Manual Lowering 743
Auxiliary Hydraulics 744
Front Selector Valve 744
Rear Selector Valve 745
Hydraulic Tank 745
Remove 746
Disassemble 747
Breather Assembly 748
Filter Assembly 749
Low Oil Indicator Switch 750
Tank Fittings 750
Clean and Inspect 750
Assemble 751
Breather Assembly 751
Filter Assembly 751
Low Oil Indicator Switch 751
Tank Fittings 751
Install 751
Specifications 752
Troubleshooting 753
toc 757
AC Motor Controllers/Display Panel 757
Safety Precautions Maintenance and Repair 758
Description 761
General 761
AC Motors 761
Motor Controllers 761
Master Controller 762
Dash Display 762
Controller Area Network Bus (CANbus) 762
AC Transistor Motor Controller Replacement 763
General 763
General Maintenance Instructions 764
Special Precautions 765
Fuses 765
Fan 766
Contactors 766
Repair 766
Master Controller Checks and Adjustments 767
Function Settings 767
General 767
Troubleshooting 769
General 769
Controller Status Light Emitting Diodes (LEDs) 770
Master Controller 770
AC Motor Controllers 770
Operator Status Messages 773
Status Codes 778
Checking the Motor Controller 832
Display Panel 832
General 832
Premium Display Panel 832
Standard Display Panel 833
Standard Display Functions and Features 833
Key-On Initialization 833
Passwords 834
Performance Modes 834
Battery Discharge Indicator (BDI) 834
Hourmeters 835
Standard Dash Display Service Menu Navigation 835
General 835
Moving Through Menu Selections 835
Editing and Adding Information 835
Access to Service Functions 836
Service Functions 836
Premium Display Functions and Features 838
Key-On Initialization 838
Passwords 838
Operator Checklist Function 838
Performance Modes 838
Battery Discharge Indicator 839
Hourmeters 839
Shelf Height Selector 839
Premium Dash Display Service Menu Navigation 840
General 840
Moving Through Menu Selections 840
Access to Service Functions 841
Service Functions 841
Connector Pin-Outs 843
System Logic Diagram 849
tables 757
Table 1 Factory Parameter Defaults 767
Table 2 Traction Parameter Defaults 768
Table 3 List of Operator Warning Messages 773
Table 4 List of Fault Messages 778
Table 5 Password Prompt Screen 834
Table 6 Password Prompt Screen 835
Table 7 Password Prompt Screen 836
Table 8 Password Prompt Screen 838
Table 9 Password Screen 838
Table 10 Password Prompt Screen 840
Table 11 Password Prompt Screen 841
General 859
Threaded Fasteners 859
Nomenclature, Threads 859
Strength Identification 860
Cotter (Split) Pins 861
Fastener Torque Tables 866
Conversion Table 868
S.V 05/24
