Yale Forklift C295 (NDR030DC, NR035DC, NR040DC) Service Manual PDF

Description

Yale Forklift C295 (NDR030DC, NR035DC, NR040DC) Service Manual – PDF DOWNLOAD

FILE DETAILS:

Yale Forklift C295 (NDR030DC, NR035DC, NR040DC) Service Manual – PDF DOWNLOAD

Language : English
Pages : 1354
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Yale Forklift C295 (NDR030DC, NR035DC, NR040DC) 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
524223769-2200YRM1128-(01-2023)-US-EN 97
Series Code / Model Designation Reference Table 105
General 107
Deutsch Crimping Tool 108
How to Strip a Wire for Use With Deutsch Crimping Tool 108
How to Crimp With the Deutsch Crimping Tool 109
Calibration Test for the Deutsch Crimping Tool 111
Deutsch Connectors 113
DT, DTM, and DTP Series Connectors 113
HD Series Connectors 156
Metri-Pack Connectors 178
Remove and Install 178
Micro-Pack Connectors 181
Weather-Pack Connectors 182
AMPSEAL Crimping Tools 184
AMP Hand Crimping Tool With Certi-Crimp 184
Description 184
Stripping Wire for Use with AMP Hand Crimping Tool 185
Insulation Crimp Adjustment 186
Maintenance and Inspection for AMP Hand Crimping Tool 186
AMP Hand Crimping Tool 186
Crimp Height Inspection 186
How to use AMP Hand Crimping Tool 187
AMP Pro-Crimper II Tool 187
Description 187
Remove and Install Die Set and Locator Assembly 188
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 188
Contact Support Adjustment 189
Crimp Height Adjustment 190
Maintenance and Inspection Procedures 190
PRO-CRIMPER II Tool 190
Crimp Height Inspection 190
How to Use AMP PRO-CRIMPER II Tool 191
AMPSEAL Connector Assemblies 192
Description for Plug Connector Assembly 192
Seal Plug 193
Contact Crimping 193
Description for Plug Connector and Header Assembly 198
Voltage Reading 201
Seal Plug 201
Contact Crimping 201
AMP Superseal 1 5 Crimping Tools 208
Mini Mic Receptacle and Tab Contacts 208
Description 208
Crimping Conditions and Measurements 208
Insertion of Rubber Seal on Cable 210
AMP Hand Application Tool 215
Description 215
Maintenance and Inspection 215
Crimp Height Inspection 215
Crimp Height Adjustment 216
How to Use AMP Hand Application Tool 216
AMP Pro-Crimper II Tool 217
Description 217
Remove and Install Die Set and Locator Assembly 217
Adjustments 218
Contact Support 218
Crimp Height 219
Inspections and Maintenance 220
Crimp Height Inspection 220
Visual Inspection 220
Maintenance 221
How to Use Pro-Crimper II Tool 221
AMP Superseal 1 5 Connector Assemblies 222
Description 222
Repair and Maintenance 229
Panel Mount Option 229
AMP Fastin-Faston Hand Tools 230
Description – AMP Double Action Hand Tool 230
Maintenance and Inspection Procedures 230
Daily Maintenance 230
Periodic Tool Inspection 231
Lubrication 231
Visual Inspection 231
Crimp Height Inspection 231
Certi-Crimp Ratchet Inspection 232
How to Use AMP Double Action Hand Tool 233
Description – AMP Extraction Tool 234
Maintenance and Inspection 235
How to Use AMP Extraction Tool 235
AMP Fastin-Faston Receptacles and Housings 237
Description 237
Wire Repair 245
Wire Splicing Requirements 245
Deutsch Jiffy Splice 246
Twisted/Shielded Cable and Leads Repair 252
Special Tools 254
524223769-2200YRM1128-(07-2020)-US-EN 263
Series Code / Model Designation Reference Table 269
General 272
Deutsch Crimping Tool 272
How to Strip a Wire for Use With Deutsch Crimping Tool 272
How to Crimp With the Deutsch Crimping Tool 273
Calibration Test for the Deutsch Crimping Tool 275
Deutsch Connectors 277
DT, DTM, and DTP Series Connectors 277
HD Series Connectors 319
Metri-Pack Connectors 342
Remove and Install 342
Micro-Pack Connectors 344
Weather-Pack Connectors 345
AMPSEAL Crimping Tools 347
AMP Hand Crimping Tool With Certi-Crimp 347
Description 347
Stripping Wire for Use with AMP Hand Crimping Tool 347
Insulation Crimp Adjustment 348
Maintenance and Inspection for AMP Hand Crimping Tool 348
AMP Hand Crimping Tool 348
Crimp Height Inspection 348
How to use AMP Hand Crimping Tool 349
AMP Pro-Crimper II Tool 349
Description 349
Remove and Install Die Set and Locator Assembly 350
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 351
Contact Support Adjustment 351
Crimp Height Adjustment 352
Maintenance and Inspection Procedures 352
PRO-CRIMPER II Tool 352
Crimp Height Inspection 352
How to Use AMP PRO-CRIMPER II Tool 353
AMPSEAL Connector Assemblies 354
Description for Plug Connector Assembly 354
Seal Plug 355
Contact Crimping 355
Description for Plug Connector and Header Assembly 360
Voltage Reading 362
Seal Plug 362
Contact Crimping 362
AMP Superseal 1 5 Crimping Tools 369
Mini Mic Receptacle and Tab Contacts 369
Description 369
Crimping Conditions and Measurements 369
Insertion of Rubber Seal on Cable 371
AMP Hand Application Tool 376
Description 376
Maintenance and Inspection 376
Crimp Height Inspection 376
Crimp Height Adjustment 377
How to Use AMP Hand Application Tool 377
AMP Pro-Crimper II Tool 378
Description 378
Remove and Install Die Set and Locator Assembly 379
Adjustments 379
Contact Support 379
Crimp Height 380
Inspections and Maintenance 381
Crimp Height Inspection 381
Visual Inspection 381
Maintenance 382
How to Use Pro-Crimper II Tool 382
AMP Superseal 1 5 Connector Assemblies 383
Description 383
Repair and Maintenance 390
Panel Mount Option 390
AMP Fastin-Faston Hand Tools 391
Description – AMP Double Action Hand Tool 391
Maintenance and Inspection Procedures 391
Daily Maintenance 391
Periodic Tool Inspection 392
Lubrication 392
Visual Inspection 392
Crimp Height Inspection 392
Certi-Crimp Ratchet Inspection 393
How to Use AMP Double Action Hand Tool 394
Description – AMP Extraction Tool 395
Maintenance and Inspection 395
How to Use AMP Extraction Tool 396
AMP Fastin-Faston Receptacles and Housings 397
Description 397
Wire Repair 404
Wire Splicing Requirements 404
Deutsch Jiffy Splice 405
Twisted/Shielded Cable and Leads Repair 410
Special Tools 413
550191462-0100YRM2082-(08-2019)-US-EN 421
General 425
Discharging the Internal Capacitors 425
Description 428
Repairs – General 429
Covers, Panels, and Plates 429
Service Access Panel 429
Removal 430
Inspection and Cleaning 430
Installation 430
Operator Compartment Covers 431
Front Covers (Left and Right) 431
Main Cover, Battery Tray Cover (With Tiller Cover), and Service Cover 432
Remove 432
Install 436
Caster Cover 436
Compartment Door Assembly 437
Inspection 438
Door Latch and Stop 438
Remove 438
Inspect 439
Install 439
Adjustment 439
Door Pad 439
Remove 440
Install 440
Operator Back Pads 440
Side-Stance Models 440
Forward-Stance Models 440
Operator Wall Pad 441
Storage Container 441
Remove 441
Base Arms and Load Wheel Boxes 441
Description 441
Inspection (Bolt-On Wheel Box) 441
Inspection (Welded Wheel Box) 442
Repair 442
Overhead Guard Replacement 442
Remove 444
Inspect 444
Install 444
Light Assemblies 444
Painting and Vinyl Wrap Instructions 445
Painting Instructions 445
Vinyl Wrap 445
Removal 446
Surface Preparation 446
Installation 447
Repair 448
Safety Labels Replacement 448
Frame Fasteners 450
Repair 450
Threaded Insert Removal 450
Inspection 450
Install 450
550191463-0620YRM2083-(08-2019)-US-EN 453
General 457
Discharging the Internal Capacitors 457
Traction Motor Repair 460
Remove 460
Disassemble 463
Clean/Inspect 468
Assemble 468
Install 469
Hydraulic Motor Repair 470
Lift Truck Models NDR030DC, NR035-040DC (C295) 470
Disassemble 470
Inspect 472
Assemble 472
Lift Truck Models NR035EC, NR040EC, NR045EC, NDR030EC, NDR035EC (E861) 472
25cc (EE Option) and 32cc Hydraulic Pumps 472
Disassemble 472
Inspect 475
Assemble 475
28/9cc Dual Pump 476
Disassemble 476
Inspect 479
Assemble 479
Auxiliary Motor Repair 480
General 480
Special Tools 481
Tool Chart 481
Troubleshooting 481
550191464-0630YRM2084-(01-2021)-US-EN 485
General 489
General 489
Description 489
Discharging The Capacitors 490
Master Drive Unit Repair 494
Maintenance 494
Draining the Oil 494
Remove 494
Clean and Inspect 499
Install 501
Replace the Wheel Seal on Kordel Drive Units 501
Tools required 501
Truck setup 501
Wheel shaft seal and protection ring removal (method 1) 501
Wheel shaft seal and protection ring removal (method 2) 502
Wheel shaft seal and protection ring installation 504
Troubleshooting 505
550191464-0630YRM2084-(09-2022)-US-EN 507
General 513
General 513
Description 514
Discharging The Capacitors 515
Master Drive Unit Repair 519
Maintenance 519
Draining the Oil 519
Remove 519
Disassemble 521
Clean and Inspect 522
Assemble 522
Install 523
Replace the Wheel Seal on Kordel Drive Units 524
Tools required 524
Truck setup 524
Wheel shaft seal and protection ring removal (method 1) 524
Wheel shaft seal and protection ring removal (method 2) 525
Wheel shaft seal and protection ring installation 526
Troubleshooting 528
550191465-1600YRM2085-(03-2020)-US-EN 531
General 535
Discharging the Capacitors 536
Raising the Lift Truck 539
How to Raise the Drive Tire End 539
How to Raise the Entire Lift Truck 540
Description 541
Steering Handle Assembly 543
Fixed Handle 543
Description 543
Remove 543
Disassemble 544
Assemble 546
Install 546
Adjustable Handle 546
Description 546
Remove 546
Disassemble 547
Assemble 550
Install 550
Steering Sensors and Steering Controllers 551
Steering Motors 551
Description 551
Remove 551
Steering Motor 551
Steered Caster Motor 552
Disassemble 554
Assemble 555
Install 555
Steering Motor 555
Steered Caster Motor 556
Caster Assembly – General 556
Caster Adjustment 556
Elastomer Spring Type Adjustment 556
Remove Spring Assembly 558
Replace Spring Pack 559
Install Spring Assembly 559
Proximity Switch Adjustment 559
Caster Wheels 560
Remove 560
Install 561
Caster Wheel Assembly (Non-steered) 562
Description 562
Remove 563
Disassemble 564
Upper and Lower Support Housings 564
Spring Assembly From Lower Support Assembly 564
Caster Spindle From Lower Support 564
Lower Support Housing 565
Upper Support Housing 566
Assemble 567
Upper Support Housing 567
Lower Support Housing 568
Caster Spindle to Lower Support 568
Spring Assembly to Lower Support 568
Upper and Lower Support Housings 569
Install 569
Caster Wheel Assembly (Steered) 570
Description 570
Remove 570
Disassemble 571
Upper and Lower Support 571
Spring Assembly From Lower Support Housing 572
Caster Spindle From Lower Support 572
Lower Support Housing 573
Upper Support Housing 574
Caster Steering Motor 574
Assemble 575
Caster Steering Motor 575
Upper Support Housing 575
Lower Support Housing 576
Caster Spindle to Lower Support 577
Spring Assembly to Lower Support 577
Upper and Lower Support Housings 577
Install 577
Troubleshooting 579
550191466-1800YRM2086-(03-2020)-US-EN 581
General 585
Discharging the Capacitors 585
Electric Brake 589
Air Gap 590
Coil Resistance Check 592
Remove 592
Install 593
Troubleshooting 594
550191466-1800YRM2086-(07-2023)-US-EN 597
General 603
Discharging the Capacitors 603
How to Put Lift Truck on Blocks 606
How to Raise Load Wheels 606
How to Raise the Drive Tire End 607
How to Raise the Entire Lift Truck 607
Electric Brake 609
Air Gap 611
Coil Resistance Check 614
Remove Single-Stage Brake Assembly 614
Remove 2-Stage Brake Assembly 615
Install Single-Stage Brake Assembly 616
Install 2-Stage Brake Assembly 617
Troubleshooting 619
550191467-1900YRM2087-(03-2020)-US-EN 621
General 625
Discharging the Capacitors 626
Description 627
Control Handle 628
Sidestance Control Handle 628
Fore/Aft Stance 629
Maintenance 630
Oil Level and Leaks 630
Operation 630
Oil Change 630
Drain 630
Cylinder Identification 631
Fill 632
Main Lift Cylinders 633
Free-Lift Cylinders 633
Breather Cap 633
Inspect 633
Hydraulic Oil Filter 634
Change 634
Oil Strainer 635
Check 635
Hydraulic System 636
General 636
Cleaning 636
Noise Levels 636
Hoses 636
Fittings 638
Hydraulic Lift Pump and Motor 638
Lift Truck Models NDR030DC, NR035-040DC (C295) Equipped With a 19cc Hydraulic Pump 638
Remove 638
Disassemble 643
Clean 644
Inspect 644
Assemble 645
Install 645
Hydraulic Control Valve Assembly 648
General 648
Remove Hydraulic Control Valve 649
Clean and Inspect Hydraulic Control Valve Assembly 652
Install Hydraulic Control Valve Assembly to Lift Truck 652
Remove, Inspect, and Install Component Parts 652
Pressure Transducer 652
Main Relief Valve 654
Pressure Test Ports 655
Port Plugs 655
Hydraulic Fittings 656
Lift, Lower, and Auxiliary Function Valves 659
General 659
Checking Operation of Function Valves 659
Remove Valves 659
Clean and Inspect 660
Install 660
Electrical Coils 661
Remove 661
Clean and Inspect 662
Install 662
Manual Lowering Valve 662
Auxiliary Hydraulics 663
Reach Carriage Hydraulics 663
Front Selector Valve 663
Remove 664
Clean and Inspect 665
Install 665
Rear Selector Valve 666
Remove 667
Clean and Inspect 668
Install 668
Hydraulic Tank 669
Remove 669
Disassemble 670
Breather Assembly 671
Filter Assembly 671
Tank Fittings 672
Clean and Inspect 673
Assemble 673
Breather Assembly 673
Filter Assembly 673
Tank Fittings 674
Install 674
Specifications 675
Troubleshooting 676
550191468-2200YRM2088-(01-2021)-US-EN 679
General 685
Discharging the Internal Capacitors 686
Static Strap 689
Inspect 689
Replace 689
Safety Procedures When Working Near Mast 690
Battery Connection 693
Inspect 693
Replacing Cables 693
Key Switch 696
General 696
Replace 696
Major Electrical System Features 697
General 697
Integrated System 698
CANbus Advantages 698
CANbus Communications 698
Electric Steering / Steer Caster (Optional) 698
Centering Proximity Sensor 698
Traction and Hydraulic Functions 698
Vehicle System Manager 699
Input Devices 699
Output Devices 699
Encoder Integrity 699
Test Encoders 699
Proximity Switches 699
Dash Display Panel 700
BDI 701
Speed 701
Steer Angle 701
Truck Hours 701
Performance Mode 701
Setup 701
Calibrations 701
AC Motor Controllers and Connecting Cables 702
General 702
Controller Removal 702
Install 705
Low-Voltage Protection Function 708
CDF File Installation Procedure 708
Contactor and Electrical Panel Checks 710
Fuse Panel and Relays 710
Contactors Inspection 711
General 711
Test 712
Tips 712
Replacing The Main Contactor 712
Remove 712
Install 715
Replacing The Freezer Contactor 715
Remove 715
Install 716
Instrument Panel and Dash Display 717
Description 717
Remove 718
Display 718
Install 718
Battery Power Disconnect Switch 719
Replace 719
Side-Stance Controls 722
Multifunction Control Handle 722
Horn 722
Inspection 723
Remove 723
Install 725
Side Stance Control Handle Disassembly and Repair 725
Handle Grip and Switch Repairs 725
Handle Grip Support Mounting 725
Handle Disassembly 726
Forward-Stance Controls 728
Control Handle Functions 728
Repair 729
Aft Travel Control Handle Option 730
Repair 731
Aft Handle Sensor Adjustment 733
Steering Handle 733
Steering Unit Repair 733
Steering Sensors and Steering Controllers 736
Steering Proximity Sensor 736
Remove 736
Adjust/Install 737
Proximity Caster Centering Sensor 738
Remove 738
Adjustment 740
Install 741
Power Steering Controller 741
Steered Caster Option 741
Remove 741
Install 741
Non-Steered Caster Option 741
Remove 741
Disassemble 743
Assemble 743
Install 743
Brake Switch 744
General 744
Repair, Cushioned and Non-Freezer Floor Plate Configuration 745
Repair, Suspended, Non-Freezer Floor Plate Configuration 746
Repair, Freezer Floor Plate Configuration 747
General 747
Operator Sensing System 750
General 750
Remove 751
Install 754
Audible Alarm and Horn 754
Horn 754
Audible Alarm 755
Light Assemblies 755
General 755
Front Headlights 756
Remove 756
Install 757
Front Blue Spot Light, Rear Work Light, and Rear Blue Spot Light 757
Remove 757
Install 758
Visible Alarm Light (Strobe Light) 758
Remove 758
Install 759
Operator Compartment Light 759
Remove 759
Install 760
Light Switches 760
Cooling Fans 760
Electrical Compartment Fans 760
Controller Cooling Fan, Replace 761
Rear Cooling Fan, Replace 762
Operator Fan 762
Repair 763
Vehicle Systems Manager, O-Box, and DC/DC Converter 764
General 764
Vehicle Systems Manager (VSM) 764
Remove 764
Install 766
O-Box (Control Module) 766
Remove 766
Install 769
DC-DC Converter 770
Remove 770
Install 771
Height Proximity Switch 771
Test 772
Remove 773
Install 773
Reach Carriage Proximity Sensor 773
General 773
Remove 774
Install 774
Adjust 774
Fork Height Sensor Option 775
Lift Trucks Equipped With 5 5-in (C567) Mast 775
Remove 775
Encoder Assembly 775
Timing Belt 776
Install 777
Encoder Assembly 777
Timing Belt 777
Lift Trucks Equipped With 9 4-in Short (E570) and Tall (D585) Mast 777
Remove 777
Install 779
Sideshift Auto Center Sensor 779
General 779
Remove 779
Install 780
Retract Sensor 780
Remove 780
Install 781
Tilt Position Sensor 782
Remove 782
Install 783
Laser Option 783
Remove 783
Adjustment 784
Horizontal Adjustment 784
Vertical Adjustment 785
Install 786
Camera Option 786
Lift Trucks Equipped With 5 5-in Mast 786
Description 786
Remove 789
Install 789
Lift Trucks Equipped With 9 4-in Mast 789
Description 789
Remove 791
Install 792
Telemetry Management System 794
General 794
Remove 794
Install 796
550191469-2200YRM2089-(01-2021)-US-EN 799
General 807
Introduction 807
Menu Navigation 809
Navigation Key 809
Arrow Keys and Scroll Bar 810
Startup Sequence 811
Password Entry 813
Adding/Changing Passwords 813
Home Screen 813
Home Screen Layout 814
Meters 814
Driving Meter 814
Dynamic Meter 814
Center Area 815
Meter Frame 815
Companion Icon 815
Unit Indicator 815
Steer Direction 815
Gauges 815
Menu Structure 819
Password Based Menus 822
Service Logging In 822
Log In 822
Enable/disable password (optional) 824
Main Menus 824
Information Menu 826
Faults Menu 827
Settings Menu 833
Performance Menu 835
Performance Parameters 836
P1 3 Travel Speed FF 836
P1 5 Travel Speed FT 836
P1 9 Travel Acceleration 836
P1 11 Neutral Braking 836
P1 13 Regen Braking 837
P1 15 Lift Speed 837
P1 19 Lower Speed 837
P1 27 Lift Acceleration 837
P1 29 Lower Acceleration 837
P1 31 Lift Deceleration 837
P1 33 Lower Deceleration 837
P1 35 Reach Mech Spd In 837
P1 37 Reach Mech Spd Out 837
P1 43 Tilt Speed Forward 837
P1 45 Tilt Speed Back 837
P1 53 Sideshift Speed 837
P1 67 Aft Handle Speed FF 838
P1 69 Aft Handle Speed FT 838
P1 71 Aft Handle Regen Braking 838
P1 73 Steer Ratio 838
Hydraulic Menu 838
Hydraulic Parameter Adjustments 838
H1 25 Carry Ht Mode 838
H1 27 Carry Ht Horn Duration 838
H2 3 RTST 838
H2 5 RTST Pause Duration 838
H2 7 RTST Override Mode 839
H2 19 RTST Stop Direction 839
H3 15 Auto Center SS 839
H9 15 Hydraulic Lockout 839
Drive Menu 839
Drive Parameter Adjustments 841
D2 1 Type 841
D2 9 BDI Reset 841
D2 11 Lift INT – Battery 841
D2 21 Ahr Capacity 841
D2 25 BDI Adjust 841
D2 39 Battery Gate Switch (Sw) 841
D4 1 Steer Effort 841
D4 3 Steer Mode 841
D4 51 Steer Speed Red En 841
D4 53 Steer Speed Red 841
D8 2 Mast Up FT Speed Limit 842
D8 3 Carr Ext Spd Red 842
D8 4 FF Spd w/Carr Ext 842
D8 5 FT Spd w/Carr Ext 842
D8 13 Simultaneity Mode 842
D8 55 Mast Up FF Speed Limit 842
Sensors/Presets Menu 842
Sensor/Presets Parameters 843
S1 1 Impact Sensor 843
S1 3 Impact OP (Operator Presence) Filter 843
S1 5 Impact Logging 843
S1 7 Mark Events Crit (Criteria) 843
S1 9 Impact Shutdown 843
S1 11 Shutdown Timeout 843
S1 13 Impact Audible Alarm 843
S1 15 Impact Visual Alarm 843
S1 17 Hard Impacts/Day 843
S1 19 Soft Impacts/Day 843
S1 21 Clear Derate Event 843
S1 23 Soft Count Threshold 843
S1 25 Soft Impact Threshold Horizontal 844
S1 27 Soft Impact Threshold Vertical 844
S1 29 Hard Impact Threshold Horizontal 844
S1 31 Hard Impact Threshold Vertical 844
Shutdown Impact Threshold Horizontal 844
Shutdown Impact Threshold Vertical 844
S3 1 Camera 1 844
S3 5 Fork Laser 844
S4 1 Shelf Height 844
S4 3 Place Offset 844
S4 5 Preset Ht (Height) 844
S4 25 Lift/Low Limit 844
S4 26 Limit Override 844
S4 27 Lift/Low Limit En 844
S4 45 Fork Height Disp 844
S5 7 Connection Type 844
Maintenance Menu 845
Maintenance Parameters 847
M1 1 Reminder Levels 847
M1 3 Level 1 847
M1 5 Level 2 847
M1 7 Level 3 847
M1 9 Level 4 847
M1 11 Level 5 847
M1 13 Level 6 847
M1 15 Derate Speed 847
M1 17 Hours Until Derate 847
M1 19 Reset All 847
M1 21 Disable All 847
M2 1 Checklist 847
M2 3 Checklist Frequency 847
M2 5 Operator Options 847
M2 7 Technical Access 847
M2 9 Shift 1 Start Time 847
M2 11 Shift 2 Start Time 847
M2 13 Shift 3 Start Time 847
M2 15 Shift 4 Start Time 847
M2 17 Question Time Limit 847
M2 19 No Response Shutdown 847
M2 21 Pre Start Overtime 848
M2 23 Post Start Overtime 848
M2 25 Pre Shutdown 848
M2 27 Post Shutdown 848
Truck Setup 848
Setting Time and Date 850
Truck Setup Parameters 851
T1 1 Units 851
T1 3 Languages 851
T1 5 Time 851
T1 7 Time Format 851
T1 15 Service Lockout 851
T1 23 Brightness 851
T1 25 Auto Dim 851
T1 50 Restore Defaults 851
T2 21 Front Blue Lt 851
T2 23 Rear Blue Lt 851
T4 5 Audible Alarm 851
Operators Menu 852
Adding New Operator 852
Adjusting Existing Operator Parameters 853
Operator Parameters 853
O1 5 Access Level 853
O1 7 Delete 853
O1 9 Allowed Performance Modes 853
Calibrations Menu 854
Calibration Parameters 856
H2c Tilt 856
H2c 3 RTST Calibration 856
H2c 11 Tilt Calibration 856
D5c Steer Axle 856
D5c 5 Steer Motor Calibration 856
D12c Throttle 856
D12c 3 Aft Throttle Range 856
S8c Height Sensor 856
S8c 1 Mast Height Calibration 856
S8c 5 Lift Enc Zero Pos 856
S12c Load Weight 856
S12c 1 Weight Scale Calibration 856
Diagnostics Menu 857
Diagnostic Parameters 860
C1d VSM/Contactor 860
C1d 1 Electronic Out 1 860
C1d 3 Electronic Out 2 860
C1d 5 Main Contactor 860
C5d Switches/Buttons 860
C5d 1 Horn Switch 860
C5d 11 Audible Alarm 860
C5d 14 Left Batt Gate SW 860
C5d 15 Right Batt Gate SW 860
C6d Occupancy 860
C6d 3 Egress Curtain 860
C6d 5 OP Left Leg Sensor 860
C6d 7 OP Right Leg Sensor 861
Current/Voltage 861
C7d 3 Power Voltage 861
C7d 4 Power Current 861
C7d 5 Sensor Voltage 861
C7d 7 Out 1 Voltage 861
C7d 8 Out 1 Current 861
C7d 9 Out 2 Voltage 861
C7d 10 Out 2 Current 861
C7d 11 Out 3 Voltage 861
C7d 12 Out 3 Current 861
C7d 13 Out 4 Voltage 861
C7d 14 Out 4 Current 861
C7d 15 Out 5 Voltage 861
C7d 17 Out 6 Voltage 861
C7d 18 Out 5 and 6 Current 861
C7d 19 Out 7 Voltage 861
C7d 21 Out 8 Voltage 861
C7d 22 Out 7 and 8 Current 861
C7d 23 Out 9 Voltage 861
C7d 25 Out 10 Voltage 861
C7d 26 Out 9 and 10 Current 861
C7d 27 In 1 Voltage 861
C7d 29 In 2 Voltage 861
C7d 31 In 3 Voltage 861
D2d Battery 861
D2d 1 Battery Voltage 861
D2d 3 State of Charge (SOC) 861
D4d Steer 862
D4d 3 Steer Angle 862
D4d 7 Steer Status 862
D4d 11 Controller Temp 862
D4d 12 Motor Temp 862
D4d 13 Motor Current 862
D4d 14 Cap Voltage 862
D4d 15 Cap Max Voltage 862
D4d 16 Cap Min Voltage 862
D4d 17 Key Voltage 862
D4d 18 Key Max Voltage 862
D4d 19 Key Min Voltage 862
D4d 20 Center Proximity Switch 862
D6d Steer (Caster) 862
D6d 3 Steer Angle 862
D6d 7 Steer Status 862
D6d 11 Controller Temperature 862
D6d 12 Motor Temperature 862
D6d 13 Motor Current 862
D6d 14 Cap Voltage 862
D6d 15 Max Cap Voltage 862
D6d 16 Min Cap Voltage 862
D6d 17 Key Voltage 862
D6d 18 Max Key Voltage 862
D6d 19 Min Key Voltage 862
D6d 20 Center Prox Switch 862
D8d Traction 862
D8d 2 Travel Speed 862
D8d 7 Motor 1 Target Speed 862
D8d 9 Motor 1 Speed 862
D8d 13 Controller 1 Temperature 863
D8d 15 Motor 1 Temperature 863
D8d 17 Motor 1 Current 863
D8d 19 Controller 1 Cap Volts 863
D8d 21 Controller 1 Cap Max Volts 863
D8d 23 Controller 1 Cap Min Volts 863
D8d 25 Controller 1 Key Volts 863
D8d 27 Controller 1 Key Max Volts 863
D8d 29 Controller 1 Key Min Volts 863
D8d 35 Brake Switch 863
D8d 41 Aft Throttle 863
D8d 43 Aft Enable Switch 863
D8d 45 Aft Horn Switch 863
H1d Lift/Lower 863
H1d 7 Lift Pressure 863
H1d 9 Lift Command 863
H1d 13 Function Switch 863
H1d 29 Prop Coil Current 863
H1d 41 Mast Prox Switch 863
H1d 43 Lift Height Sensor 863
H1d 45 Hoist Select Coil Status 863
H1d 47 Lift Coil Status 863
H1d 49 Load Hold Coil Status 863
H2d Tilt 863
H2d 4 Command 863
H2d 17 Tilt Coil Status 863
H3d 3rd Hydraulic Function 863
H3d 4 3rd Command 863
H3d 15 Return Position Proximity Sensor 863
H3d 17 3rd Hydraulic Coil Status 863
H4d 4th Hydraulic Function 864
H4d 4 4th Command 864
H4d 15 4th Hydraulic Coil Status 864
H8d Pump 864
H8d 1 Controller Temp 864
H8d 3 Motor Temp 864
H8d 5 RMS Motor Current 864
H8d 11 Target Motor Speed 864
H8d 13 Motor Speed 864
H8d 31 Mast Prox Switch 864
H8d 33 Aux Motor Target Speed 864
H8d 35 Aux Motor Speed 864
H8d 37 Aux Motor Temperature 864
H8d 39 Aux Motor Current 864
Hour Meters 864
View Hour Meters 864
Hardware and Software Versions 865
View Hardware and Software Versions 865
Interlocks 866
General 866
Switched Inputs and Preset Heights 868
General 868
Setting Preset Heights 869
550191471-4000YRM2091-(03-2020)-US-EN 873
General 877
Description 878
Lowering Control Valve 879
Safety Procedures When Working Near Mast 881
Main Lift Cylinder Repair 882
Remove 882
Disassemble 884
Clean and Inspect 886
Clean 886
Inspect 886
Assemble 887
Install 888
Main Lift Cylinder Leak Check 889
Free-Lift Cylinder Repair 889
Remove 889
Disassemble 891
Clean 892
Inspect 892
Assemble 892
Install 892
Sideshift Cylinder Repair 893
General 893
Remove 893
Disassemble 895
Clean and Inspect 895
Assemble 895
Install 895
Reach Cylinder Repair 896
Remove 896
Disassemble 899
Clean and Inspect 899
Assemble 899
Install 900
Reach Cylinder Adjustments 900
Tilt Cylinder Repair 901
Lift Chains 903
Clean and Inspect 903
Troubleshooting 905
550191472-4000YRM2092-(03-2020)-US-EN 907
General 911
Safety Procedures When Working Near Mast 914
Mast Weldments 917
Reach Carriage Assembly 919
Three-Stage Mast 921
Description 921
Operation 923
550191473-4000YRM2093-(03-2020)-US-EN 927
General 931
Safety Procedures When Working Near Mast 933
Load Backrest 934
Remove 934
Install 935
Forks 935
Remove 936
Install 936
Checks 936
Hose And Chain Sheaves 938
Load Rollers 940
Mast Load Rollers 940
Remove 940
Clean and Inspect 941
Install 941
Reach Carriage Assembly 941
Reach Carriage Assembly Remove and Install 941
Description 941
Remove 943
Inspect 945
Install 947
Mast Repair 947
Remove 947
Disassemble 953
Clean and Inspect 954
Assemble 955
Install 956
Mast Lubrication 957
Header Hose Installation and Adjustment 958
Remove 958
Installation 959
Lift Chains 962
Clean and Inspect 962
Mast Adjustments 964
General 964
Mast Back Angle Adjustment 964
Load Rollers Adjustment 965
Reach Carriage Assembly 965
Adjust Wear Plugs – Mast 966
Adjust Main-Lift Chains 967
Adjust Free-Lift Chain 969
Mast Side Kicking (Racking) 971
Proximity Switches 972
Mast Operation Check 973
550191474-4500YRM2094-(03-2020)-US-EN 975
General 979
Safety Procedures When Working Near Mast 980
Description 981
Load Backrest 982
Remove 982
Install 983
Forks 983
Remove 984
Install 984
Checks 984
Load Rollers 986
Remove 986
Clean and Inspect 987
Install 987
Reach Carriage Assembly Repair 988
General 988
Reach Carriage Front Frame 988
Remove 988
Disassemble 993
Reach Trucks Equipped With Sideshift Option 993
Reach Trucks Equipped Without Sideshift Option 994
Clean and Inspect 996
Assemble 996
Reach Trucks Equipped With Sideshift Option 996
Reach Trucks Equipped Without Sideshift Option 996
Install 997
Single-Reach Scissor Arms 997
Remove 997
Disassemble 997
Clean and Inspect 999
Assemble 999
Double-Reach Scissor Arms 999
Remove 999
Disassemble 999
Clean and Inspect 1003
Assemble 1003
Reach Carriage Rear Frame 1005
Remove 1005
Disassemble 1005
Clean and Inspect 1005
Assemble 1006
Install 1006
Reach Carriage Adjustments 1006
Check Adjustment 1006
Load Rollers Adjustment 1007
Cylinder Adjustments 1008
Extend Distance Adjustment 1008
Extend Arm Adjustment 1009
Lift Chains 1010
Specifications 1011
Troubleshooting 1012
550191475-8000YRM2095-(01-2021)-US-EN 1015
General 1021
General 1021
Discharging the Internal Capacitors 1022
Removing Covers and Door, Side-Stance 1026
Removing Covers and Door, Fore/Aft Stance 1029
Installing Door and Covers, Side-Stance 1032
Installing Door and Covers, Fore/Aft Stance 1032
How to Move Disabled Truck 1032
How to Tow Lift Truck 1032
How to Put Lift Truck on Blocks 1035
How to Raise Load Wheels 1035
How to Raise the Drive Tire End 1036
How to Raise the Entire Lift Truck 1036
Manual Lowering Valve 1036
NR035-045EC, NDR030-35EC (E861) 1036
NDR030DC, NR035-040DC (C295) 1037
Transporting 1038
Loading 1038
Unloading 1038
Preparation for Use 1039
Preparation After Shipment 1039
Preparation After Storage 1039
Safety Procedures When Working Near Mast 1039
Maintenance Schedule 1042
Maintenance Procedures Every 8 Hours or Daily 1054
Checks With Key Switch Turned OFF 1054
Hydraulic System 1054
Forks 1055
Forks, Remove 1055
Forks, Check 1055
Forks, Install 1057
Forks, Adjust 1057
Inspection of Mast and Lift Chains 1057
Reach, Tilt, and Sideshift 1058
Caster Adjustment 1058
Safety Labels 1058
Battery 1059
Tires and Wheels 1059
Frame and Load Wheels 1060
Overhead Guard 1060
Static Strap 1060
Checks With Key Switch Turned ON 1061
Horn and Battery Indicator 1061
Fuses and Relays 1061
Operation 1062
Control Levers and Pedals 1063
Lift System Operation 1063
Multifunction Control Handle 1065
Brake 1065
Steering System 1065
Maintenance Procedures Every 500 Hours or 3 Months 1066
Hydraulic System 1066
Hydraulic Filter Change 1067
Master Drive Unit 1069
Adding Oil To Master Drive Unit (MDU) 1069
Changing Oil In Master Drive Unit (MDU) 1069
Caster Adjustment 1070
Elastomer Spring Type Adjustment 1070
Spring Pack Replacement 1073
Remove Spring Assembly 1073
Replace Spring Pack 1074
Install Spring Assembly 1075
Load Wheels 1075
Load Wheel Bolts 1075
Load Wheel Saddle Pin 1076
Drive Tire Check 1076
Lift System Operation 1076
Forks 1077
Mast 1077
Lift Chains 1077
Electrical System 1078
Power Cables and Electrical Connections 1078
Other Lubrication 1078
Maintenance Procedures Every 2000 Hours or Yearly 1079
Electric System 1079
Main Contactor 1079
Inspect 1079
Freezer Contactor 1080
Remove 1080
Install 1081
Hydraulic System 1082
Drain 1082
Cylinder Identification 1084
Fill 1085
Main Lift Cylinders 1085
Free-Lift Cylinders 1086
Hydraulic Filter Change 1087
Check Hydraulic Strainer 1088
Lift and Tilt System Leaks Check 1089
Lift System 1089
Tilt System 1089
Battery Maintenance 1090
How to Charge Battery 1090
How to Change Battery 1091
Tires and Wheels 1094
Drive Tire 1094
How to Change Drive Tire 1094
Tandem Load Wheels 1095
Welded Wheel Box 1095
Remove 1095
Install 1096
Bolt-On Wheel Box 1096
Remove 1096
Install 1097
Caster Wheels 1097
Remove 1097
Install 1098
Preparation for Storage 1099
Short-Term Storage (1 to 6 months) 1099
Long-Term Storage (6 months or longer) 1099
550191475-8000YRM2095-(07-2023)-US-EN 1101
General 1109
General 1109
Discharging the Internal Capacitors 1109
Removing Covers and Door, Side-Stance 1112
Removing Covers and Door, Fore/Aft Stance 1116
Installing Door and Covers, Side-Stance 1118
Installing Door and Covers, Fore/Aft Stance 1119
How to Move Disabled Truck 1119
How to Tow Lift Truck 1119
How to Put Lift Truck on Blocks 1120
How to Raise Load Wheels 1120
How to Raise the Drive Tire End 1121
How to Raise the Entire Lift Truck 1121
Manual Lowering Valve 1122
NR035-045EC, NDR030-35EC (E861) 1122
NDR030DC, NR035-040DC (C295) 1122
Transporting 1124
Loading 1124
Unloading 1124
Preparation for Use 1125
Preparation After Shipment 1125
Preparation After Storage 1125
Safety Procedures When Working Near Mast 1126
Maintenance Schedule 1130
Maintenance Procedures Every 8 Hours or Daily 1144
Checks With Key Switch Turned OFF 1144
Hydraulic System 1144
Forks 1145
Forks, Remove 1145
Forks, Check 1145
Forks, Install 1147
Forks, Adjust 1147
Inspection of Mast and Lift Chains 1147
Reach, Tilt, and Sideshift 1148
Caster Adjustment 1148
Safety Labels 1148
Battery 1149
Tires and Wheels 1149
Frame and Load Wheels 1150
Overhead Guard 1150
Static Strap 1150
Checks With Key Switch Turned ON 1151
Horn and Battery Indicator 1151
Fuses and Relays 1151
Operation 1152
Control Levers and Pedals 1153
Lift System Operation 1153
Multifunction Control Handle 1155
Brake 1155
Steering System 1156
Maintenance Procedures Every 500 Hours or 3 Months 1157
Hydraulic System 1157
Hydraulic Filter Change 1158
Master Drive Unit 1160
Adding Oil To Master Drive Unit (MDU) 1160
Changing Oil In Master Drive Unit (MDU) 1160
Caster Adjustment 1162
Elastomer Spring Type Adjustment 1162
Spring Pack Replacement 1166
Remove Spring Assembly 1166
Replace Spring Pack 1167
Install Spring Assembly 1167
Load Wheels 1167
Load Wheel Bolts 1167
Load Wheel Saddle Pin 1169
Drive Tire Check 1169
Lift System Operation 1169
Forks 1170
Mast 1170
Lift Chains 1170
Electrical System 1170
Power Cables and Electrical Connections 1170
Other Lubrication 1171
Maintenance Procedures Every 2000 Hours or Yearly 1172
Electric System 1172
Main Contactor 1172
Inspect 1172
Freezer Contactor 1173
Remove 1173
Install 1174
Hydraulic System 1175
Drain 1175
Cylinder Identification 1177
Fill 1178
Main Lift Cylinders 1179
Free-Lift Cylinders 1179
Hydraulic Filter Change 1181
Check Hydraulic Strainer 1182
Brake System 1182
Air Gap Check 1182
Lift and Tilt System Leaks Check 1183
Lift System 1183
Tilt System 1183
Battery Maintenance 1184
How to Charge Battery 1184
How to Change Battery 1185
Tires and Wheels 1188
Drive Tire 1188
How to Change Drive Tire 1188
Tandem Load Wheels 1189
Welded Wheel Box 1189
Remove 1189
Install 1190
Bolt-On Wheel Box 1190
Remove 1190
Install 1191
Caster Wheels 1191
Remove 1191
Install 1193
Preparation for Storage 1194
Short-Term Storage (1 to 6 months) 1194
Long-Term Storage (6 months or longer) 1194
550191476-8000YRM2096-(03-2020)-US-EN 1197
Lubrication Specifications 1201
Oil Capacities 1201
Hydraulic System 1202
Mast Speeds 1203
Carriage Speeds 1205
Carriage Operating Times 1207
Forks 1211
Steering System 1211
Brake System 1212
Traction Motor Speeds 1212
Tire Sizes 1213
Torque Specifications 1214
Master Drive Unit 1214
Reach Carriage 1214
Mast 1214
Hydraulic System 1214
Steering System 1214
Load Wheels 1214
Fuses 1215
Coil Resistance Values 1215
Battery Specifications 1217
550191476-8000YRM2096-(03-2022)-US-EN 1219
Lubrication Specifications 1225
Oil Capacities 1225
Hydraulic System 1226
Mast Speeds 1226
Carriage Speeds 1229
Carriage Operating Times 1231
Forks 1235
Steering System 1235
Brake System 1236
Traction Motor Speeds 1236
Tire Sizes 1238
Torque Specifications 1239
Master Drive Unit 1239
Reach Carriage 1239
Mast 1239
Hydraulic System 1239
Steering System 1239
Load Wheels 1239
Fuses 1240
Coil Resistance Values 1240
Battery Specifications 1241
550191477-8000YRM2097-(03-2020)-US-EN 1243
Schematic/Diagram 1247
Electrical Schematics 1247
Hydraulic Schematics 1279
550191477-8000YRM2097-(04-2022)-US-EN 1287
Schematic/Diagram 1293
Electrical Schematics 1293
Hydraulic Schematics 1325
550267564-0630YRM2448-(09-2022)-US-EN 1333
General 1339
General 1339
Description 1339
Discharging The Capacitors 1340
Master Drive Unit Repair 1344
Maintenance 1344
Draining the Oil 1344
Remove 1344
Disassemble 1346
Clean and Inspect 1347
Assemble 1347
Install 1348
Replace the Wheel Seal on Kordel Drive Units 1348
Tools required 1348
Truck setup 1348
Wheel shaft seal and protection ring removal (method 1) 1349
Wheel shaft seal and protection ring removal (method 2) 1349
Wheel shaft seal and protection ring installation 1351
Troubleshooting 1352

S.V 05/24