Yale Forklift C861 (NR045EA, NDR035EA) Service Manual – PDF DOWNLOAD

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Yale Forklift C861 (NR045EA, NDR035EA) Service Manual – PDF DOWNLOAD

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Yale Forklift C861 (NR045EA, NDR035EA) Service Manual – PDF DOWNLOAD

Language : English
Pages : 944
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Yale Forklift C861 (NR045EA, NDR035EA) 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
524164473-4000YRM0481-(08-2016)-US-EN 97
General 101
Description 101
Lowering Control Valve 102
Main Cylinder Repair 103
Disassemble 104
Assemble 105
Free-Lift Cylinder Repair 106
Disassemble 106
Assemble 106
Troubleshooting 108
524166250-0630YRM1022-(08-2009)-US-EN 111
toc 111
Master Drive Unit 111
Safety Precautions Maintenance and Repair 112
HFK400 Master Drive Unit 115
General 115
Description 115
Drive Unit Maintenance and Repair 116
Remove 116
Install 117
Disassemble 117
Assemble 121
Troubleshooting 129
GK Master Drive Unit 131
General 131
Description 131
Maintenance 132
Changing the Oil 132
Traction Motor and Drive Unit Splines 132
Remove 132
Assemble 133
Mounting Electric Motor 134
Pivoted Connection – Geared Steering 134
Disassemble 135
Install 135
Troubleshooting 136
tables 111
Table 1 Tooth Contact Pattern 126
524183085-2200YRM1058-(04-2011)-US-EN 139
toc 139
Troubleshooting and Adjustments Using the AC Controls Program (E 139
Safety Precautions Maintenance and Repair 140
General 143
Computer Requirements 143
Software, Install 143
Language Selection 143
Demo Mode 144
Connect PC to Lift Truck 148
Starting AC Controls Program 150
Lift Truck Control Setup 155
Change Lift Truck Serial Number or Hourmeter 155
Setting Factory Default Values or Changing Lift Truck Parameters 156
Create New Custom Lift Truck Configuration 162
Lift Truck Configuration Properties 165
Import New Lift Truck Configuration From Disk 168
Delete Custom Lift Truck Configuration or Password File 170
Dash Display 173
Custom Display Languages 173
Download Display Language 175
Clear Operator Log 175
Password Functions 178
Enable/Disable Password and Lift Truck Inspection Functions 178
Truck Inspection Checklist 178
Password 178
Password Properties 178
Create New Password File 183
Download Passwords 184
Upload Passwords 186
Reports Menu 188
Devices Report 188
Custom Report 188
Password Report 188
Operator Report 195
Current Settings Report 198
Status Code Report 202
Status Codes Log 205
Troubleshooting 207
Diagnostics 207
Help Menu 210
General 210
Contents 210
Technical Support 210
About Electric Truck AC Controls Program 210
524233332-1600YRM1187-(09-2009)-US-EN 217
toc 217
Steering System 217
Safety Precautions Maintenance and Repair 218
General 221
Discharging the Capacitors 222
Raising the Lift Truck 223
How to Raise the Drive Tire End 223
How to Raise the Entire Lift Truck 224
Description 224
Steering Handle Assembly 227
Fixed Handle 227
Description 227
Remove 227
Disassemble 229
Assemble 231
Install 231
Adjustable Handle 232
Description 232
Remove 232
Disassemble 232
Assemble 236
Install 236
Steering Controller 237
Description 237
Remove 237
Disassemble 237
Assemble 238
Install 238
Steering Proximity Switch 238
Replace 238
Steering Motor 239
Description 239
Remove 239
Disassemble 240
Assemble 240
Install 240
Caster Assembly – General 241
Caster Adjustment 241
Elastomer Spring Type Adjustment 241
Belleville Spring Type Adjustment 242
Spring Pack Replacement 244
Remove Spring Assembly 244
Replace Spring Pack 245
Install Spring Assembly 245
Caster Wheels 246
Remove 246
Install 246
Caster Wheel Assembly (Nonsteered) 247
Description 247
Remove 248
Disassemble 249
Upper and Lower Support Housings 249
Spring Assembly From Lower Support Assembly 249
Caster Spindle From Lower Support 249
Caster Wheels 250
Lower Support Housing 250
Upper Support Housing 251
Assemble 252
Upper Support Housing 252
Lower Support Housing 253
Caster Wheels 253
Caster Spindle to Lower Support 254
Spring Assembly to Lower Support 254
Upper and Lower Support Housings 254
Install 254
Caster Assembly (Steered) 256
Description 256
Remove 256
Disassemble 258
Upper and Lower Support 258
Spring Assembly From Lower Support Housing 258
Caster Spindle From Lower Support 258
Caster Wheels 259
Lower Support Housing 260
Upper Support Housing 261
Caster Steering Motor 261
Assemble 262
Caster Steering Motor 262
Upper Support Housing 262
Lower Support Housing 263
Caster Wheels 264
Caster Spindle to Lower Support 264
Spring Assembly to Lower Support 265
Upper and Lower Support Housings 265
Install 266
Troubleshooting 267
tables 217
Table 1 Caster Specifications 242
Table 2 Upper Adjustment Gap Measurement 244
524233333-0100YRM1185-(03-2011)-US-EN 271
toc 271
Frame 271
Safety Precautions Maintenance and Repair 272
General 275
Description 275
Repairs – General 276
Covers, Panels, and Plates 276
Front Frame Panel (Left and Right) 276
Operator Compartment Cover 277
Drive Unit Compartment Door 277
Door Pad 277
Operator Back Pad 277
Side-Stance Models 277
Forward-Stance Models 277
Operator Front Pad 278
Caster Wheel Cover 278
Load Wheels 278
Remove 278
Install 278
Overhead Guard Replacement 279
Remove 283
Install 283
Front Lights 283
Bulb Replacement 283
Assembly Replacement 284
Rear Work and Caution Light 285
Caution Light 285
Painting Instructions 286
Safety Labels Replacement 287
524233334-0620YRM1186-(08-2009)-US-EN 293
toc 293
AC Motor Repair 293
Safety Precautions Maintenance and Repair 294
General 297
Traction Motor Repair 298
Disassemble 298
Inspect 299
Assemble 299
Drive End Bearing, Replace 300
Hydraulic Motor Repair 301
Disassemble 301
Inspect 303
Assemble 304
Troubleshooting 305
tables 293
Table 1 Traction Motor Windings 299
Table 2 Hydraulic Motor Windings 304
524233335-1800YRM1188-(01-2016)-US-EN 309
Introduction 313
General 313
Discharging the Capacitors 313
Electric Brake 314
Air Gap 315
Remove 316
Install 317
Troubleshooting 318
524233336-1900YRM1189-(09-2010)-US-EN 323
toc 323
Hydraulic System 323
Safety Precautions Maintenance and Repair 324
General 327
Discharging the Capacitors 329
Description 329
Control Handle 330
Sidestance Control Handle 330
Fore/Aft Stance 331
Maintenance 332
Oil Level and Leaks 332
Operation 332
Oil Change 332
Drain 332
Cylinder Identification 334
Fill 335
Main Lift Cylinders 335
Free-Lift Cylinders 336
Breather Cap 336
Inspect 336
Oil Filter 337
Change 337
Oil Strainer 337
Check 337
Hydraulic System 338
General 338
Cleaning 338
Noise Levels 338
Hoses 338
Fittings 340
Lift Pump and Motor 341
Complete Unit 341
Remove 341
Install 342
Lift Pump 344
Components 344
Pressure Flange Fitting 344
Supply and Return Fittings 345
Manual Lowering Valve 345
Pressure Test Ports 346
Pressure Transducer 346
Relief Valve 348
Lowering Control Valve 349
Remove Pump 349
Install Pump 349
Auxiliary Hydraulics 350
Auxiliary Pump and Motor 350
Remove 350
Disassemble 351
Assemble 352
Install 352
Front Selector Valve 353
Rear Selector Valve 354
Hydraulic Tank 355
Remove 355
Disassemble 356
Breather Assembly 356
Filter Assembly 358
Low Oil Indicator Switch 359
Tank Fittings 360
Clean and Inspect 360
Assemble 360
Breather Assembly 360
Filter Assembly 360
Low Oil Indicator Switch 360
Tank Fittings 360
Install 361
Specifications 362
Troubleshooting 362
tables 323
Table 1 Main Lift Pump and Motor Configurations 329
Table 2 Cylinder Identification 335
524233337-2200YRM1190-(10-2010)-US-EN 367
toc 367
AC Motor Controllers/Display Panel 367
Safety Precautions Maintenance and Repair 368
Description 371
General 371
AC Motors 371
Motor Controllers 371
Master Controller 372
Dash Display 372
Controller Area Network Bus (CANbus) 372
AC Transistor Motor Controller Replacement 373
General 373
General Maintenance Instructions 374
Special Precautions 375
Fuses 375
Fan 376
Contactors 376
Repair 376
Master Controller Checks and Adjustments 377
Function Settings 377
General 377
Troubleshooting 379
General 379
Controller Status Light Emitting Diodes (LEDs) 380
Master Controller 380
AC Motor Controllers 380
Operator Status Messages 383
Status Codes 386
Checking the Motor Controller 458
Display Panel 458
General 458
Premium Display Panel 458
Standard Display Panel 458
Standard Display Functions and Features 460
Key-On Initialization 460
Passwords 460
Performance Modes 461
Battery Discharge Indicator (BDI) 461
Hourmeters 461
Standard Dash Display Service Menu Navigation 462
General 462
Moving Through Menu Selections 462
Editing and Adding Information 462
Access to Service Functions 463
Service Functions 463
Premium Display Functions and Features 465
Key-On Initialization 465
Passwords 465
Operator Checklist Function 465
Performance Modes 465
Battery Discharge Indicator 466
Hourmeters 466
Shelf Height Selector 466
Premium Dash Display Service Menu Navigation 467
General 467
Moving Through Menu Selections 467
Access to Service Functions 468
Service Functions 468
Connector Pin-Outs 470
System Logic Diagram 477
tables 367
Table 1 Factory Parameter Defaults 377
Table 2 Traction Parameter Defaults 378
Table 3 List of Operator Warning Messages 383
Table 4 List of Fault Messages 387
Table 5 Password Prompt Screen 460
Table 6 Password Reminder Screen 460
Table 7 Password Prompt Screen 462
Table 8 Password Prompt Screen 463
Table 9 Password Prompt Screen 465
Table 10 Password Screen 465
Table 11 Password Prompt Screen 467
Table 12 Password Prompt Screen 468
524233338-2200YRM1191-(11-2008)-US-EN 481
toc 481
Electrical System 481
Safety Precautions Maintenance and Repair 482
General 487
Discharging the Capacitors 488
Static Strap 488
Inspect 488
Replace 488
Battery Connection 489
Inspect 489
Replacing Cables 489
Key Switch 490
Replace 490
Contactors 492
Function 492
Testing 493
Remove 493
Install 494
EE Contactors 494
Motor Controllers 495
Functions 495
Master Controller 495
Steering Motor Controller 495
Traction Motor Controller 495
Lift Motor Controller 495
Steer Caster Controller (Optional) 495
Replace 495
Traction and Lift Motor Controllers 496
Master Controller 496
Steering Controller 496
Steer Caster Controller (Option) 497
Integrated Fuse Board (IFB) 497
Fuses 498
Replace 498
Power Disconnect Switch 499
Replace 499
Side-Stance Controls 500
Multifunction Control Handle 500
Remove 501
Disassemble 501
Assemble 503
Install 503
Forward-Stance Controls 504
Control Handle Functions 504
Repair 504
Aft Travel Control Handle Option 506
Repair 507
Steering Handle 508
Steering Unit Repair 508
Foot Switches 512
Brake Switch 512
Operator Sensing 512
Repair 512
Dash Display Assembly 513
Description 513
Remove 514
Test 515
Install 515
Horn 516
Audible Alarm 516
Light Assemblies 517
Front Lights 517
Bulb Replacement 517
Assembly Replacement 517
Rear Work and Caution Light 518
Rear Work Light 518
Caution Light 518
Light Switches 519
Cooling Fans 521
Electrical Compartment Fans 521
Replace 521
Operator Fan 523
Repair 523
Impact Sensor 525
Remove 525
Install 525
Height Proximity Switch 526
Test 526
Remove 526
Install 527
Adjust 527
Load Transport Proximity Switch 528
Replace 528
Adjust 529
Fork Height Sensor Option 529
Remove 529
Encoder Assembly 529
Timing Belt 530
Install 531
Encoder Assembly 531
Timing Belt 532
Reach Position Sensor 532
Remove 532
Install 534
Retract Sensor 535
Remove 535
Install 535
Tilt Leveling 537
Remove 537
Install 537
Laser Option 538
Remove 538
Install 538
Camera Option 539
Remove 539
Install 539
Wiring Harness 539
524233339-2200YRM1192-(11-2012)-US-EN 547
toc 547
User Interface 547
Safety Precautions Maintenance and Repair 548
General 551
Description 551
Dash Display Menu Access 551
Menu Navigation 552
Standard Display 552
Main Menu 552
Diagnostics Menu 553
Static Diagnostics 553
Traction System 557
Hydraulic System 558
Steer System 561
Error Log 562
View Hourmeters 562
View Software Versions 562
Master Controller 562
Display 563
Traction Controller 563
Hydraulic Controller 564
Control Handle 564
Remote CAN Module ( NDR035EA, NR045EA, NDR030EA, NR035/040EA ) 565
Steer Controller 565
Caster Controller 566
Aux Pump ( NDR035EA, NR045EA, NDR030EA, NR035/040EA ) 566
Impact Sensor 566
Functions 568
Impact Action 568
Impact Sound 568
Clear Impact 568
Hard Duration 568
Hard Acceleration 568
Soft Duration 568
Soft Acceleration 569
Impact Events 569
Passwords Menu 569
Add Password 570
Delete Password 571
Edit Password 572
tables 547
Table 1 Static Diagnostics Menu 553
Table 2 Traction System Diagnostics Menu 557
Table 3 Hydraulic System Diagnostics Menu 558
Table 4 Steering System Diagnostics Menu 561
Table 5 Error Log 562
Table 6 Master Controller Software Version 562
Table 7 Display Software Version 563
Table 8 Traction Controller Software Version 563
Table 9 Hydraulic Controller Software Version 564
Table 10 Control Handle Software Version 564
Table 11 Remote CAN Module Software Version 565
Table 12 Steer Controller Software Version 565
Table 13 Caster Controller Software Version 566
Table 14 Aux Pump Controller Software Version 566
Table 15 Impact Sensor Data Display 567
524233340-2200YRM1193-(11-2012)-US-EN 575
toc 575
User Interface 575
Safety Precautions Maintenance and Repair 576
General 579
Description 579
Dash Display Menu Access 579
Menu Navigation 580
Standard Display 580
Main Menu 580
Diagnostics Menu 580
Static Diagnostics 580
Traction System 584
Hydraulic System 585
Steer System 588
General Truck 589
Error Log 590
View Hourmeters 590
Truck Hours 590
Traction Hours 591
Pump Hours 591
Auxiliary Hours 592
Setup Menu 592
Lift Settings 592
Lift Maximum Speed ( NDR035EA, NR045EA, NDR030EA, NR035/040EA ) 592
Lower Maximum Speed ( NDR035EA, NR045EA, NDR030EA, NR035/040EA ) 593
Auxiliary Settings 593
Fast Extend Speed 593
Slow Extend Speed 594
Fast Retract Speed 594
Slow Retract Speed 595
Tilt Up Speed 595
Tilt Down Speed 596
Sideshift Speed 596
Reach Cushioning 597
Steer Settings 597
Steer Mode 597
Steer Effort 598
Steer Ratio 598
Truck Settings 599
Truck Serial Number 599
Truck Voltage 599
Truck Capacity 600
Battery Type 600
BDI Adjust 601
Extended Shift 601
Lift Limit Without Override ( NDR035EA, NR045EA, NDR030EA, NR035 602
Lift Limit With Override ( NDR035EA, NR045EA, NDR030EA, NR035/04 602
Audible Alarm 603
Visible Alarm 604
Autotilt Option 604
Laser Option 605
Carry Level Option 605
Slow Extended 606
Simultaneous Hydraulics 606
Password Option 607
Shutdown Timeout 607
Traction Settings 608
Rabbit Speed 608
Rabbit Acceleration 608
High Speed 609
High Acceleration 609
Mid Speed 610
Mid Acceleration 610
Turtle Speed 611
Turtle Acceleration 611
Neutral Braking 612
Plug Braking 612
View Software Versions 613
Master Controller 613
Display 613
Traction Controller 614
Hydraulic Controller 614
Control Handle 615
Remote CAN Module ( NDR035EA, NR045EA, NDR030EA, NR035/040EA ) 615
Steer Controller 616
Caster Controller 616
Aux Pump ( NDR035EA, NR045EA, NDR030EA, NR035/040EA ) 617
Impact Sensor 618
Functions 618
Functions 619
Impact Action 619
Impact Sound 619
Clear Impact 619
Hard Duration 619
Hard Acceleration 619
Soft Duration 619
Sort Acceleration 619
Impact Events 619
Password Menu 620
Add Password 621
Delete Password 622
Edit Password 623
tables 575
Table 1 Password Screen 579
Table 2 Static Diagnostics Menu 581
Table 3 Traction System Diagnostics Menu 584
Table 4 Hydraulic System Diagnostics Menu 585
Table 5 Steering System Diagnostics Menu 588
Table 6 General Truck Diagnostics Menu 589
Table 7 Error Log 590
Table 8 Truck Hours 590
Table 9 Traction Hours 591
Table 10 Pump Hours 591
Table 11 Auxiliary Hours 592
Table 12 Lift Maximum Speed Menu 592
Table 13 Lower Maximum Speed Menu 593
Table 14 Fast Extend Speed Menu 593
Table 15 Slow Extend Speed Menu 594
Table 16 Fast Retract Speed Menu 594
Table 17 Slow Retract Speed Menu 595
Table 18 Tilt Up Speed Menu 595
Table 19 Tilt Down Speed Menu 596
Table 20 Sideshift Speed Menu 596
Table 21 Cushioning Speed Menu 597
Table 22 Steer Mode Menu 597
Table 23 Steer Effort Menu 598
Table 24 Steer Ratio Menu 598
Table 25 Truck Serial Number Menu 599
Table 26 Truck Voltage Menu 599
Table 27 Truck Capacity Menu 600
Table 28 Truck Type Menu 600
Table 29 BDI Adjust Menu 601
Table 30 Extended Shift Menu 601
Table 31 Lift Limit Without Override 602
Table 32 Lift Limit With Override 602
Table 33 Audible Alarm Menu 603
Table 34 Visible Alarm Menu 604
Table 35 Autotilt Option Menu 604
Table 36 Laser Option 605
Table 37 Carry Level Option Menu 605
Table 38 Restore Defaults Menu 606
Table 39 Simultaneous Hydraulics Menu 606
Table 40 Password Option Menu 607
Table 41 Shutdown Timeout Menu 607
Table 42 Rabbit Speed Menu 608
Table 43 Rabbit Acceleration Menu 608
Table 44 High Speed Menu 609
Table 45 High Acceleration Menu 609
Table 46 Mid Speed Menu 610
Table 47 Mid Acceleration Menu 610
Table 48 Turtle Speed Menu 611
Table 49 Turtle Acceleration Menu 611
Table 50 Neutral Braking Menu 612
Table 51 Plug Braking Menu 612
Table 52 Master Controller Software Version 613
Table 53 Display Software Version 613
Table 54 Traction Controller Software Version 614
Table 55 Hydraulic Controller Software Version 614
Table 56 Control Handle Software Version 615
Table 57 Remote CAN Module Software Version 615
Table 58 Steer Controller Software Version 616
Table 59 Caster Controller Software Version 616
Table 60 Aux Pump Controller Software Version 617
Table 61 Impact Sensor Data Display 618
524233341-4000YRM1194-(01-2016)-US-EN 627
General 631
Safety Procedures When Working Near Mast 632
Mast Weldments 634
Reach Carriage Assembly 634
Three-Stage Mast 636
Description 636
Operation 637
524233342-4000YRM1195-(07-2019)-US-EN 641
General 645
Safety Procedures When Working Near Mast 645
Load Backrest 646
Remove 646
Install 646
Forks 646
Remove 647
Install 647
Checks, Lift Truck Models NR045EA, NDR035EA (C861); NR035EA, NR040EA, NDR030EA (D815); NR035DA, NR040DA, NDR030DA (A295) 647
Checks, Lift Truck Models NR045EB, NDR035EB (D861); NR035EB, NR040EB, NDR030EB (E815); NR035DB, NR040DB, NDR030DB (B295) 648
Sheaves 650
Hydraulic System 653
Hydraulic Oil 655
Drain 655
Cylinder Identification 657
Fill 658
Main Lift Cylinders 659
Free-Lift Cylinders 659
Reach Carriage Assembly 660
Remove 660
Install 662
Load Rollers 663
Mast 663
Reach Assembly 665
Load Rollers 665
Side Rollers 665
Mast 666
Remove 666
Disassemble 667
Clean and Inspect 668
Assemble 669
Install 671
Lift Cylinders 672
Main Lift Cylinders 672
Remove 672
Install 675
Free-Lift Cylinder 676
Remove 676
Install 677
Lift Chains 678
Clean and Inspect 678
Mast Adjustments 679
General 679
Mast Back Angle Adjustment 679
Load Rollers Adjustment 680
Reach Carriage Assembly 680
Adjust Wear Plugs – Mast 681
Adjust Main-Lift Chains 683
Adjust Free-Lift Chain 683
Adjust Wear Strips 685
Mast Racking 686
Proximity Switches 687
Replace 688
Free-Lift Proximity Switch 688
Load Lowering Proximity Switch (Optional) 689
Adjust 689
Mast Operation Check 689
Lift System Leak Check 690
Lift Cylinder Leak Check 690
Tilt Cylinder Leak Check 690
524233343-4500YRM1196-(01-2016)-US-EN 693
General 697
Safety Procedures When Working Near Mast 697
Description 698
Repair – General 700
Load Backrest 700
Remove 700
Install 700
Forks 701
Replacement 701
Remove 701
Install 701
Reach Carriage Assembly 702
Remove 702
Inspect 703
Install 704
Reach Carriage Assembly Repair 704
Load Rollers Repair 705
Side Rollers Repair (6 9 Mast Only) (NDR030DA and NR035/040DA) 706
Reach Assembly Front Frame 707
Remove 707
Disassemble (With Sideshift) 708
Disassemble (Without Sideshift) 710
Clean and Inspect 711
Assemble (With Sideshift) 711
Assemble (Without Sideshift) 711
Install 712
Single-Reach Scissor Arms 712
Remove and Disassemble 712
Clean and Inspect 716
Assemble and Install 716
Double-Reach Scissor Arms 718
Disassemble 718
Clean and Inspect 722
Assemble 722

Rear Frame Assembly 725
Remove 725
Disassemble 727
Clean and Inspect 728
Assemble 728
Install 728
Reach Cylinders 730
Remove 730
Disassemble 731
Clean and Inspect 732
Assemble 732
Install 733
Tilt Cylinder 733
Remove 733
Clean, Inspect, and Repair 734
Install 735
Sideshift Cylinder 735
Repair 735
Front Selector Valve 736
Rear Selector Valve 737
Reach Assembly Adjustments 737
Check Adjustment 738
Adjust Side Rollers and Load Rollers 739
Adjust Reach Cylinders 740
Lift Chains 741
Inspect 741
Clean and Lubricate 742
Adjust Main-Lift Chains 742
Adjust Free-Lift Chains 742
Specifications 743
Troubleshooting 746
524233344-8000YRM1197-(08-2009)-US-EN 751
toc 751
Periodic Maintenance 751
Safety Precautions Maintenance and Repair 752
General 755
Removing Covers 755
Front Frame Panel (Left and Right) 755
Operator Compartment Cover 756
Drive Unit Compartment Door 757
Caster Wheel Cover 757
Discharging the Capacitors 757
How to Move Disabled Truck 758
How to Tow Lift Truck 758
How to Put Lift Truck on Blocks 759
How to Raise Load Wheels 759
How to Raise the Drive Tire End 760
How to Raise the Entire Lift Truck 760
Manual Lowering Valve 760
NDR030/035EA and NR030/040/045EA 760
NDR030DA and NR035/040DA 761
Transporting 762
Loading 762
Unloading 762
Preparation for Use 763
Preparation After Shipment 763
Preparation After Storage 763
Safety Procedures When Working Near Mast 763
Maintenance Schedule 764
Maintenance Procedures Every 8 Hours or Daily 769
Checks With Key Switch Turned OFF 769
Battery 769
Tires and Wheels 770
Frame and Load Wheels 770
Safety Labels 770
Overhead Guard 771
Forks Check 771
Lift Chain Check 772
Mast Check 773
Reach, Tilt, and Sideshift 773
Checks With Key Switch Turned ON 773
Operation 773
Hydraulic System 774
Dash Display 774
Lift System Operation 775
Multifunction Control Handle 776
Brake 776
Steering System 776
Maintenance Procedures Every 500 Hours or 3 Months 777
Master Drive Unit 777
Hydraulic System 777
Hydraulic Filter Element Change 779
Caster Adjustment 779
Elastomer Spring Type Adjustment 779
Belleville Spring Type Adjustment 781
Spring Pack Replacement 782
Remove Spring Assembly 782
Replace Spring Pack 783
Install Spring Assembly 783
Drive Tire Check 783
Lift System Operation 784
Forks 784
Mast 784
Lift Chains 784
Other Lubrication 784
Maintenance Procedures Every 2000 Hours or Yearly 785
Brakes 785
Check 785
Electric System 785
Main Contactor 785
Inspect 785
Master Drive Unit 786
Hydraulic System 786
Drain 786
Cylinder Identification 787
Fill 789
Main Lift Cylinders 789
Free-Lift Cylinders 790
Hydraulic Filter Change 791
Check Hydraulic Strainer 791
Lift and Tilt System Leaks Check 792
Lift System 792
Tilt System 792
Battery Maintenance 793
How to Charge Battery 793
How to Change Battery 794
Tires and Wheels 796
Drive Tire 796
How to Change Drive Tire 797
Tandem Load Wheels 798
Caster Wheels 798
Remove 798
Install 799
Preparation for Storage 800
Short-Term Storage (1 to 6 months) 800
Long-Term Storage (6 months or longer) 800
tables 751
Table 1 Maintenance Schedule 765
Table 2 Fork Tip Alignment 771
Table 3 Hydraulic Tank Capacities 778
Table 4 Caster Specifications 780
Table 5 Upper Adjustment Gap Measurement 782
Table 6 Free-Lift Cylinder Rod Widths 789
Table 7 Battery Size Specifications 796
Table 8 Tires and Wheels 797
524233345-8000YRM1198-(05-2008)-US-EN 803
toc 803
Capacities and Specifications 803
Safety Precautions Maintenance and Repair 804
Lubrication Specifications 807
Oil Capacities 807
Hydraulic System 808
Lift Specifications 809
Tire Sizes 814
Torque Specifications 814
Master Drive Unit 814
Reach Carriage 814
Mast 814
Hydraulic System ( NDR030/035EA and NR030/040/045EA ) 815
Hydraulic System ( NDR030DA and NR035/040DA ) 815
Steering System 815
Load Wheels 815
Fuses 815
Coil Resistance Values 816
Battery Specifications 817
524233346-8000YRM1199-(12-2013)-US-EN 821
524260263-2200YRM1240-(11-2008)-US-EN 885
toc 885
User Interface 885
Safety Precautions Maintenance and Repair 886
General 889
Description 889
Dash Display Menu Access 889
Menu Navigation 890
Main Menu 890
Diagnostics Menu 890
Static Diagnostics 890
Traction System 892
Hydraulic System 892
Steer System 893
Error Log 894
View Hourmeters 895
Truck 895
Traction 895
Pump 895
Auxiliary 895
Setup Menu 896
Display Settings 896
Display Language 896
Year, Month, Date, Hour, Minute, and Second 896
View Software Versions 896
Master Controller 896
Display 897
Traction Controller 897
Hydraulic Controller 897
Control Handle 897
Remote CAN Module ( NDR035EA, NR045EA, NDR030EA, NR035/040EA Onl 897
Steer Controller 897
Caster Controller 897
Aux Pump 897
Passwords Menu 898
View Operator Log 898
Add Password 900
Delete Password 901
Edit Password 902
Setup Shelf Height 903
Learn Shelf Height 903
Impact Sensor 904
Functions 905
Impact Action 905
Impact Sound 905
Clear Impact 905
Hard Duration 905
Hard Acceleration 905
Soft Duration 905
Soft Acceleration 906
Impact Events 906
Maintenance Reminder 906
Functions 906
Maintenance Reminder 906
Maintenance Interval 906
tables 885
Table 1 Enter Password Screen 889
Table 2 Static Diagnostics Menu 891
Table 3 Traction System Menu 892
Table 4 Hydraulic System Menu 892
Table 5 Steer System Menu 893
Table 6 Impact Sensor Data Display 904
524260264-2200YRM1241-(11-2008)-US-EN 909
toc 909
User Interface 909
Safety Precautions Maintenance and Repair 910
General 915
Description 915
Dash Display Menu Access 915
Menu Navigation 916
Main Menu 916
Diagnostics Menu 916
Static Diagnostics 916
Traction System 918
Hydraulic System 918
Steer System 919
General Truck 920
Height Sensor 920
Calibrate Fork Tare Down 920
Calibrate Fork Tare Up 920
Calibrate Cushion Inpoint ( NDR035EA, NR045EA, NDR030EA, NR035/0 921
Calibrate Cushion Outpoint ( NDR035EA, NR045EA, NDR030EA, NR035/ 921
Calibrate Mast Slowdown 921
Error Log 921
View Hourmeters 922
Truck 922
Traction 922
Pump 922
Auxiliary 922
Setup Menu 923
Lift Settings 924
Lift Maximum Speed ( NDR035EA, NR045EA, NDR030EA, NR035/040EA ) 924
Lower Maximum Speed ( NDR035EA, NR045EA, NDR030EA, NR035/040EA ) 924
Lift Acceleration 924
Auxiliary Settings 925
Fast Extend Speed 925
Slow Extend Speed 925
Fast Retract Speed 925
Slow Retract Speed 926
Tilt Up Speed 926
Tilt Down Speed 926
Sideshift Speed 926
Reach Cushioning 926
Steer Settings 926
Steer Mode 927
Steer Effort 927
Steer Ratio 927
Display Settings 927
Display Language 927
Year, Month, Date, Hour, Minute, and Second 927
Truck Settings 928
Serial Number 928
Voltage 928
Capacity Lbs 928
Battery Type 928
BDI Adjust Calibration 928
Extended Shift 929
Shelf Height Selection 929
Load Weight Option ( NDR035EA, NR045EA, NDR030EA, NR035/040EA ) 929
Lift Limit Without Override ( NDR035EA, NR045EA, NDR030EA, NR035 929
Lift Limit With Override 929
Audible Alarm 929
Visible Alarm Option 929
Fork Height Display 930
Auto Tilt Option 930
Laser Option 930
Carry Level Option 930
Slow Extended 930
Simultaneous Hydraulics 930
Password Option 930
Shutdown Timeout 930
Truck Inspection 930
Traction Settings 930
Rabbit Speed 930
Rabbit Acceleration 931
High Speed 931
High Acceleration 931
Mid Speed 931
Mid Acceleration 931
Turtle Speed 931
Turtle Acceleration 931
Neutral Braking 932
Plug Braking 932
View Software Versions 932
Master Controller 932
Display 932
Traction Controller 932
Hydraulic Controller 932
Control Handle 933
Remote CAN Module ( NDR035EA, NR045EA, NDR030EA, NR035/040EA ) 933
Steer Controller 933
Caster Controller 933
Aux Pump 933
Passwords Menu 933
Functions 934
View Operator Log 934
Add Password 934
Delete Password 936
Edit Password 936
Setup Shelf Height 937
Learn Shelf Height 938
Impact Sensor 938
Functions 940
Impact Action 940
Impact Sound 940
Clear Impact 940
Hard Duration 940
Hard Acceleration 940
Soft Duration 940
Soft Acceleration 940
Impact Events 940
Maintenance Reminder 941
Functions 941
Maintenance Reminder 941
Maintenance Interval 941
tables 909
Table 1 Enter Password Screen 915
Table 2 Static Diagnostics Menu 917
Table 3 Traction System Menu 918
Table 4 Hydraulic System Menu 918
Table 5 Steer System Menu 919
Table 6 General Truck Menu 920
Table 7 Impact Sensor Data Display 939

S.V 05/24