Yale Forklift B861 (NDR030GB, NR045GB) Service Manual – PDF DOWNLOAD

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Yale Forklift B861 (NDR030GB, NR045GB) Service Manual – PDF DOWNLOAD

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Yale Forklift B861 (NDR030GB, NR045GB) Service Manual – PDF DOWNLOAD

Language : English
Pages : 604
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Yale Forklift B861 (NDR030GB, NR045GB) Service Manual – PDF DOWNLOAD

524150797-8000YRM0231-(02-2023)-US-EN 1
General 7
Threaded Fasteners 7
Nomenclature, Threads 7
Strength Identification 8
Cotter (Split) Pins 9
Fastener Torque Tables 14
Conversion Table 16
524150797-8000YRM0231-(03-2020)-US-EN 23
General 27
Threaded Fasteners 27
Nomenclature, Threads 27
Strength Identification 28
Cotter (Split) Pins 29
Fastener Torque Tables 34
Conversion Table 36
524158040-2240YRM0001-(01-2023)-US-EN 43
General 49
Battery Type 49
Lead-Acid Batteries 49
Lithium-Ion Batteries 50
Specific Gravity 50
Chemical Reaction in a Cell 50
Electrical Terms 52
Battery Selection 53
Battery Voltage 54
Battery as a Counterweight 54
Battery Ratings 54
Kilowatt-Hours 54
Battery Maintenance 55
Safety Procedures 55
Maintenance Records 55
New Battery 55
Cleaning Battery 56
Adding Water to Battery 58
Hydrometer 58
Battery Temperature 59
Charging Battery 60
Types of Battery Charges 61
Methods of Charging 62
Troubleshooting Charger 63
Knowing When Battery Is Fully Charged 63
Where to Charge Batteries 63
Equipment Needed 63
Battery Connectors 64
Battery Care 64
Troubleshooting 66
524158040-2240YRM0001-(03-2020)-US-EN 71
General 75
Battery Type 75
Lead-Acid Batteries 75
Lithium-Ion Batteries 76
Specific Gravity 76
Chemical Reaction in a Cell 76
Electrical Terms 78
Battery Selection 78
Battery Voltage 79
Battery as a Counterweight 80
Battery Ratings 80
Kilowatt-Hours 80
Battery Maintenance 80
Safety Procedures 80
Maintenance Records 81
New Battery 81
Cleaning Battery 81
Adding Water to Battery 83
Hydrometer 84
Battery Temperature 85
Charging Battery 86
Types of Battery Charges 86
Methods of Charging 88
Troubleshooting Charger 88
Knowing When Battery Is Fully Charged 89
Where to Charge Batteries 89
Equipment Needed 89
Battery Connectors 90
Battery Care 90
Troubleshooting 92
524164462-0100YRM0975-(07-2002)-US-EN 97
toc 97
Frame 97
Safety Precautions Maintenance and Repair 98
General 101
Description 101
Repairs – General 101
Covers, Panels, and Plates 101
Replace Load Wheels 103
Overhead Guard Repair 106
Changes to Overhead Guard 107
Remove 107
Install 107
Painting Instructions 107
Safety Labels Replacement 108
tables 97
Table 1 Unit and Model Numbers 101
524164464-1600YRM0974-(07-2002)-US-EN 113
toc 113
Steering System 113
Safety Precautions Maintenance and Repair 114
General 117
Description 117
Steering Control Unit Assembly 118
Description 118
Remove 118
Steering Control Unit 118
Description 118
Operation 118
Remove 119
Repair 119
Disassemble (Before May 2002) 119
Disassemble (After May 2002) 120
Clean 122
Reassemble (Before May 2002) 123
Reassemble (After May 2002) 123
Install 124
Steering Pump and Motor Assembly 124
Description 124
Pump and Motor 124
Remove and Disassemble 124
Assemble and Install 125
Pump 125
Remove 125
Install 126
Disassemble 126
Assemble 127
Axle Assembly Repair 128
General 128
Traction Motor 128
Description 128
Remove 128
Install 128
Master Drive Unit 129
Description 129
Remove Chain-Steered MDU 129
Install 129
Hydraulic Steering Motor 130
Description 130
Remove 130
Install 131
Caster Wheels 132
Description 132
Caster Replacement 132
Wheel Replacement 133
Axle Weldment 133
Remove 133
Install 133
Check and Adjust 134
Remove Air From Steering System 134
Check Steering Chain 134
Check Articulation Stop Adjustment 134
Steering Pressure 136
Troubleshooting 138
tables 113
Table 1 Articulation Adjustment Chart 135
524164465-1800YRM0976-(07-2002)-US-EN 143
toc 143
Brake System 143
Safety Precautions Maintenance and Repair 144
General 147
Brake Assembly 147
Remove and Disassemble 147
Assemble and Install 150
Master Cylinder and Pedal Assembly 151
Remove and Disassemble 151
Assemble and Install 151
Floor Plate Assembly 153
Remove and Disassemble 153
Assemble and Install 153
Master Cylinder 153
Disassemble 153
Assemble 153
Slave Cylinder 155
Disassemble 155
Assemble 155
Brake Switch Replacement 156
Brake Adjustment 157
Brake System Air Removal 157
Troubleshooting 157
524164466-1800YRM0983-(07-2002)-US-EN 161
toc 161
Brake System 161
Safety Precautions Maintenance and Repair 162
General 165
Brake Assembly 165
Inspect 165
Friction Pads 165
Remove 165
Install 166
Brake Assembly 167
Remove 167
Install 167
Brake Pedal Assembly 168
Remove 168
Install 169
Repair 169
Bushings and Spring 169
Remove 169
Install 169
Brake Switch Assembly 169
Remove 169
Install 169
Adjust 169
Troubleshooting 170
524164467-1900YRM0973-(12-2004)-US-EN 173
toc 173
Hydraulic System 173
Safety Precautions Maintenance and Repair 174
General 177
Description 177
Control Handle 178
Description 178
Control Valve 179
Description 179
Trucks Built Before 15 July, 2002 179
Trucks Built After 15 July, 2002 179
Control Valve-Manual Lowering 179
Trucks Built Before 15 July, 2002 179
Trucks Built After 15 July, 2002 180
Remove 180
Install 180
Check and Adjust 181
Main Relief Valve (NDR030AE, NR035/040/045AE, NS040/050AF, NDR03 181
Main Relief Valve (NDR030GB, NR045GB) 181
Auxiliary Relief Valve 182
Lift Pump and Motor 183
Description 183
Remove 183
Install 185
Disassemble 185
Assemble 186
Steering Pump 186
Hydraulic Tank 186
Description 186
Remove and Disassemble 186
Assemble and Install 187
Troubleshooting 188
tables 173
Table 1 Hydraulic Tank Capacities 186
524164468-2200YRM0977-(08-2005)-US-EN 197
toc 197
SEM Traction Motor Controller 197
Safety Precautions Maintenance and Repair 198
SEM Traction Motor Controller 201
Description/Features 201
Remove 201
Test 202
Install 202
1307 Programmer Handset 203
Description/Features 203
SCROLL DISPLAY Keys 204
CHANGE VALUE Keys 204
MORE INFO Key 204
Operation 204
Connecting Handset to Traction Motor Controller 204
Disconnecting Handset From Traction Motor Controller 205
Programmer Self Test 205
Operating Modes 205
Program Menu 205
Test Menu 206
Diagnostics Menu 207
Diagnostic History 207
Special Program Menu 207
Programming the Traction Motor Controller – 1307 Handset 208
1311 Programmer Handset 211
Description/Features 211
Menu Navigation Key 211
Data Increase/Decrease Key 212
Bookmark Keys 212
Operation 212
Connecting Handset to Traction Motor Controller 212
Disconnecting the Handset From the Traction Motor Controller 212
Main Menu Selections 213
Program Menu 213
Monitor Menu 213
Faults Menu 214
Functions menu 214
Information Menu 215
Programmer Setup Menu 215
Programming the Traction Motor Controller – 1311 Handset 215
Troubleshooting 216
Status LED Diagnostics 216
Diagnostics Menu 217
Test Menu 227
tables 197
Table 1 Program Menu 206
Table 2 Test Menu 206
Table 3 Dash Display Drive Mode Inputs 207
Table 4 Diagnostics and Diagnostic History Display 207
Table 5 Special Program Menu 208
Table 6 Program Menu Range and Default Values 209
Table 7 Status LED Fault Codes 217
524164469-2200YRM0978-(05-2005)-US-EN 233
toc 233
Electrical System 233
Safety Precautions Maintenance and Repair 234
General 239
Component Repair and Testing – General 240
Contactor Panel Assembly 240
Description/Features 240
Remove 240
Install 241
Contactors 241
Description/Features 241
Auxiliary Switch 242
Testing 242
Remove 243
Install 243
EE Contactors 243
Fuses 245
Relays 246
Description/Features 246
Enable Relay 246
Hourmeter Relay 246
Lift/Lower Relay (Trucks Built After 1 August 2002) 246
Coil Testing 246
Contact Testing 247
Remove and Install 247
Height Proximity Switch 248
Remove 248
Test 248
Install 249
Adjust 249
Key Switch 249
Description 249
Remove 249
Install 249
Battery Disconnect Switch 250
Description 250
Remove 250
Install 250
Proportional Electro-Hydraulic Control Valves 251
Manual Lowering 251
Trucks Built Before 1 August, 2002 251
Trucks Built After 1 August, 2002 252
Operation 252
Repair 252
Carriage Valve Assembly and Selector Valves 252
Test/Remove/Install 253
Multifunction Control Handle 253
Description/Features 253
Remove 254
Disassemble 255
Tools Required 255
Assemble 257
Install 257
Shelf Height Selector 258
Description/Features 258
Shelf Height Selector 258
Power On, Start Up 258
Programming 258
Field Program Mode 258
Enter Shelf Level 258
Set Shelf Level 259
Quick Pick Level Keys 259
Set Minimum Lift Speed 259
Set Minimum Lower Speed 259
Changing the 3-Digit Security Code 259
Factory Program Mode 260
Calibrate Lift 260
Set Options 260
Control Zone 261
Deadband 261
Reset User Code 261
Clear All 261
Show All Levels 261
Set LCD Bias 261
Show Analog 261
External Inputs 261
System Errors 262
Main Interface Board (MIB) Adjustments 262
Function 32 Hydraulic Potentiometer – Set-Up 262
Function 02 Lift Minimum Rate 262
Function 04 Lower Minimum Rate 262
Function 59 Hydraulic Lift Function – Stopping Rate 262
Function 61 Hydraulic Lower Function – Stopping Rate 263
Main Interface Board (MIB) 263
Description/Features 263
Operation 263
LED Display 264
MIB, Remove 264
MIB J-Connector, Repair 265
Inspect 265
MIB, Install 266
Main Interface Board (MIB) Setup Procedures 267
General 267
Default Values 267
Checking Model Code, Software Version, and Setup Status 267
MIB Generation II Setup Procedure 267
Entering the Setup Mode 267
Editing Settings 267
Changing the Setting Values 268
Entering Text 268
System Information and Fault Log 268
Passwords 268
Defaults 268
Exit and Save 268
Parameters 269
Top Level Menu Items 269
Options 269
Handle Deadband 269
Lift/Lower 269
Speeds 270
Auxiliary 270
Max Speed and Low End Adjustments 271
Customizing MIB Functions 271
MIB Status, Warning, and Fault Codes 284
General 284
Troubleshooting Charts 285
Blank or Undefined Code Conditions 286
Status Codes 290
Warning Codes 294
Fault Codes 298
SEM Traction Motor Controller 307
Description/Features 307
Remove 307
Test 308
Install 308
1307 Programmer Handset 310
Description/Features 310
SCROLL DISPLAY Keys 310
CHANGE VALUE Keys 310
MORE INFO Key 310
Operation 311
Connecting Handset to Traction Motor Controller 311
Disconnecting Handset from Traction Motor Controller 311
Programmer Self Test 311
Operating Modes 312
Program Menu 312
Test Menu 313
Diagnostics Menu 313
Diagnostic History 314
Special Program Menu 314
Programming the Traction Motor Controller – 1307 Handset 315
1311 Programmer Handset 317
Description/Features 317
Menu Navigation Key 318
Data Increase/Decrease Key 318
Bookmark Keys 318
Operation 318
Connecting Handset to Traction Motor Controller 318
Disconnecting the Handset From the Traction Motor Controller 319
Main Menu Selections 319
Program Menu 319
Monitor Menu 320
Faults Menu 320
Functions menu 321
Information Menu 321
Programmer Setup Menu 322
Programming the Traction Motor Controller – 1311 Handset 322
Troubleshooting 323
Status LED Diagnostics 323
Programmer Diagnostics 324
Diagnostics Menu 325
Test Menu 334
Dash Display Assembly 337
Description and Features 337
Operation 338
Battery Indicator 338
Remove 339
Install 339
Voltage Selection 340
Dash Display, Adjust 340
Battery Indicator Profile Settings 341
Troubleshooting 341
Inoperative Dash Display Assembly 341
Inoperative Drive Mode Selection 341
Troubleshooting the Dash Display With a Programmer Handset 342
Troubleshooting Without a Programmer Handset 342
No Warnings or Faults Displayed 342
Lift Interrupt 343
Lost MIB Signal Displayed 343
Hourmeter Input 343
tables 233
Table 1 Contactor Coil Voltages 242
Table 2 Fuses 246
Table 3 Hydraulic Control Valve/Relay Coil Resistance Values 247
Table 4 OPTS Bits 260
Table 5 Truck Unit and Model Codes 267
Table 6 MIB Function Code Values for NR035AE Software 06/01/01 271
Table 7 MIB Function Code Values for NR040AE 06/01/01 to 01/14/ 272
Table 8 MIB Function Code Values for NDR030AE 273
Table 9 MIB Function Code Values for NS050AF 274
Table 10 MIB Function Code Values for NR045CB 274
Table 11 MIB Function Code Values for NDR030CB 275
Table 12 MIB Function Code Values for NR045GB Mast Full Height 276
Table 13 MIB Function Code Values for NR045GB Mast Full Height 276
Table 14 MIB Function Code Values for NDR030GB Mast Full Height 277
Table 15 MIB Function Code Values for NDR030GB Mast Full Height 277
Table 16 MIB Software 01/14/02 to 03/27/02 NR/NDR AE, NSAF (C81 278
Table 17 MIB Software 01/14/02 to 03/27/02 NR/NDRCB and GB (D82 279
Table 18 MIB Software Post 03/27/02 NR/NDRAE C815 280
Table 19 MIB Software Post 03/27/02 NR/NDRCA (D829) and NR/NDRC 282
Table 20 NR/NDRGA (B861) 283
Table 21 Program Menu 312
Table 22 Test Menu 313
Table 23 Dash Display Drive Mode Inputs 313
Table 24 Diagnostic and Diagnostic History Display 313
Table 25 Special Program Menu 314
Table 26 Program Menu Range and Default Values 316
Table 27 Status LED Fault Codes 323
Table 28 Dash Display Drive Mode Inputs 342
Table 29 Dash Display Drive Mode Test Voltages 342
Table 30 Dash Display Status/Warning/Fault Test Voltages 343
524164470-4000YRM0480-(08-2016)-US-EN 347
General 351
Mast Weldments 353
Carriages 354
Two-Stage Mast 356
Description 357
Operation 362
Three-Stage Mast 363
Description 363
Operation 366
524164471-4000YRM0482-(05-2018)-US-EN 371
General 375
Safety Procedures When Working Near Mast 375
Load Backrest Extension, Carriage, Load Rollers, Side Rollers, and Forks 376
Load Backrest Extension, Remove and Install 377
Carriage Assembly, Remove and Install 377
Carriage Load Rollers, Remove and Install 380
Side Rollers, Disassemble and Assemble 380
Fork, Replace 381
Hook-Type Forks 381
Remove 381
Install 381
Forks Check 381
Two-Stage Mast Assembly 384
Remove 384
Clean and Inspect 389
Lift Cylinders, Remove and Install Dual-Lift Cylinders 390
Lift Cylinder, Remove and Install Single Main-Lift Cylinders 391
Remove 391
Install 392
Inner Mast Assembly, Remove and Install 393
Hoses, Replace 393
Hose and Cable Sheaves, Replace 393
Two-Stage Lift Chains 395
Remove and Install 395
Clean and Inspect 395
Two-Stage Chain Sheave, Remove and Install 396
Load Rollers and Wear Plugs, Remove and Install 396
Two-Stage Mast Assembly, Install 397
Three-Stage Mast Assembly 398
Three-Stage Mast Assembly, Remove 398
Clean and Inspect 399
Free-Lift Cylinder, Remove and Install 402
Main Cylinders (Standard), Remove and Install 403
Inner and Intermediate Mast Assemblies, Remove and Install 405
Hoses, Replace 405
Hose and Cable Sheaves, Replace 407
Free-Lift Hose Sheave 407
Carriage Sheaves 407
Three-Stage Lift Chains, Remove and Install 408
General 408
Free-Lift Chains 408
Main-Lift Chains 408
Three-Stage Chain Sheaves, Disassemble and Assemble 409
Free-Lift Chain Sheaves 409
Main-Lift Chain Sheaves 409
Load Rollers and Wear Plugs, Remove and Install 409
Three-Stage Mast Assemble, Install 410
Mast Operation Check 411
Hydraulic System Leaks Check 411
Lift Chains Check 412
General 412
Clean and Inspect 412
Lubrication 413
Mast Adjustments 413
General 414
Adjust Wear Plugs – Mast 414
Adjust Free-Lift Chain (Three-Stage Only) 416
Adjust Main-Lift Chains 416
Two-Stage 416
Three-Stage 418
Adjust Wear Strips 418
Carriage Adjustments 419
Adjust Wear Plug – Carriage 419
Adjust Side Rollers – Carriage 419
Adjust Thrust Rollers – Carriage 420
Troubleshooting 421
524164473-4000YRM0481-(08-2016)-US-EN 425
General 429
Description 429
Lowering Control Valve 430
Main Cylinder Repair 431
Disassemble 432
Assemble 433
Free-Lift Cylinder Repair 434
Disassemble 434
Assemble 434
Troubleshooting 436
524164474-4500YRM0971-(05-2018)-US-EN 439
General 443
Safety Procedures When Working Near Mast 443
Description 445
Reach Assemblies 445
Repair – General 447
Load Backrest Removal and Installation 447
Fork Replacement 448
Hook Forks 448
General 448
Remove 448
Install 449
Forks Check 449
Reach Assembly Removal and Installation 451
Carriage Load Rollers Removal and Installation 451
Side Rollers Disassembly and Assembly 453
Reach Assembly Repair 453
Reach Assembly Outer Frame 453
Remove 453
Disassemble 456
Clean and Inspect 457
Assemble 457
Install 457
Remove Without Sideshifter 457
Disassemble Without Sideshifter 458
Clean and Inspect 458
Assemble Without Sideshifter 459
Install Without Sideshifter 459
Single-Reach Scissor Arms 460
Remove and Disassemble 460
Clean and Inspect 463
Assemble and Install 463
Double-Reach Scissor Arms 464
Remove and Disassemble 464
Clean and Inspect 468
Assemble and Install 468

Frame AssemblyInner 469
Remove 471
Disassemble 472
Clean and Inspect 473
Assemble 473
Install 474
Reach Cylinders 475
Remove 475
Disassemble 476
Clean and Inspect 476
Assemble 477
Install 477
Tilt Cylinder 477
Remove 477
Clean, Inspect, and Repair 478
Install 479
Sideshift Cylinder 480
Remove 480
Clean and Inspect 480
Reach/Tilt Selector Valve 480
Remove 480
Disassemble 480
Clean and Inspect 481
Assemble 481
Install 481

Reach Assembly AdjustmentsCarriage or 481
Adjust Wear Plug 481
Adjust Side Rollers 483
Adjust Thrust Rollers 484
Adjust Reach Cylinders 484
Specifications 485
Troubleshooting 488
(NDR030GB, NR045GB, NDR030AE,NR035/040/045AE, NDR030CB, NR045CB and NS040/050AF) 488
(MRW020/030-E) 489
524164475-8000YRM0970-(09-2013)-US-EN 493
toc 493
Periodic Maintenance 493
Safety Precautions Maintenance and Repair 494
General 497
Discharging the Capacitors 497
How to Move Disabled Truck 498
How to Tow Lift Truck 498
How to Put Lift Truck on Blocks 499
How to Raise Load Wheels 499
How to Raise Steer Wheel 499
How to Raise the Entire Lift Truck 499
Safety Procedures When Working Near Mast 500
Maintenance Schedule 501
Maintenance Procedures Every 8 Hours or Daily 507
Checks With Key Switch Turned OFF 507
Battery 507
Hydraulic System 508
Tires and Wheels 510
Safety Labels 510
Overhead Guard 510
Mast, Forks, and Lift Chains 511
Reach, Tilt, and Sideshift 513
Forks 513
Remove 513
Install 514
Lift Chain Adjustments 514
Checks With Key Switch Turned ON 516
Operation 516
Instruments and Controls 516
Lift System Operation 519
Multifunction Control Handle 519
Brake 520
C815, C816, and D829 520
B861 520
Steering System 521
Maintenance Procedures Every 350 Hours or 2 Months 521
Master Drive Unit 521
Brake 521
C815, C816, and D829 521
B861 521
Hydraulic System 522
Articulation Stop Adjustment 522
Adjustment Procedure 523
Lift System Operation 523
Forks 523
Mast 523
Lift Chains 523
Other Lubrication 525
Electrical Inspection 525
Fuses 525
Contactors 526
Motor Brushes 526
Maintenance Procedures Every 2000 Hours or Yearly 528
Hydraulic System 528
Change Hydraulic Oil 528
Change Hydraulic Oil Filter 528
Check Hydraulic Oil Strainer 528
Brakes 528
Maintenance Procedures Every 3000 Hours or Three Years 529
Traction Motor 529
Lift and Tilt System Leaks Check 529
Lift System 529
Tilt System 530
Brakes Adjustment 530
C815, C816, and D829 530
B861 530
Battery Maintenance 532
How to Charge Battery 532
How to Change Battery 533
Tires and Wheels 536
Drive Tire 536
How to Change Drive Tire 536
Tandem Load Wheels 537
Single Load Wheel 537
Caster Wheels 538
C815, C816, and D829 538
B861 539
Preparation for Storage 540
Short-Term Storage (1 to 6 months) 540
Long-Term Storage (6 months or longer) 540
Transporting 541
Loading 541
Unloading 542
Preparation for Use 543
Preparation After Shipment 543
Preparation After Storage 543
tables 493
Table 1 Maintenance Schedule 504
Table 2 Articulation Adjustment Chart 522
Table 3 Fuses 525
Table 4 Hydraulic Tank Capacities 528
Table 5 Battery Size Specifications 535
Table 6 Tires and Wheels 536
524164476-8000YRM0972-(10-2007)-US-EN 547
toc 547
Capacities and Specifications 547
Safety Precautions Maintenance and Repair 548
SEM Traction Motor Controllers Factory Values and Min/Max Ranges 551
Lift Capacities 552
Articulation Adjustment 553
Master Drive Unit Specifications 553
Oil Capacities 553
Lubrication Specifications 554
Hydraulic Systems Specifications 554
Reach Carriage Specifications 555
Battery Size Specifications 556
Tire Sizes 557
Fuses 557
Steering Pump Specifications 557
Hydraulic Control Valve/Relay Coil Resistance Values 558
524164478-8000YRM0982-(02-2007)-US-EN 561
toc 561
Diagrams 561
Safety Precautions Maintenance and Repair 562
524166250-0630YRM1022-(08-2009)-US-EN 577
toc 577
Master Drive Unit 577
Safety Precautions Maintenance and Repair 578
HFK400 Master Drive Unit 581
General 581
Description 581
Drive Unit Maintenance and Repair 582
Remove 582
Install 583
Disassemble 583
Assemble 587
Troubleshooting 595
GK Master Drive Unit 597
General 597
Description 597
Maintenance 598
Changing the Oil 598
Traction Motor and Drive Unit Splines 598
Remove 598
Assemble 599
Mounting Electric Motor 600
Pivoted Connection – Geared Steering 600
Disassemble 601
Install 601
Troubleshooting 602
tables 577
Table 1 Tooth Contact Pattern 592

S.V 05/24