Yale Electric Reach Truck: NDR030AE, NR035AE, NR040AE, NR045AE [C815], NS040AF, NS050AF [C816] Service Manual

PARTS MANUAL NDR 030 AE, NR 035 AE, NR 040 AE, NR 045 AE (C815) NS 040 AF, NS 050 AF (C816) Yale Materials Handling Corporation 1400 Sullivan Drive Caller No. 12011 Greenville, NC 27834-2011 P/N 524143974 © Yale Corp. 07/2002

MODEL NOMENCLATURE NOTE: This parts manual contains alternate pages for certain assemblies. The truck model code can be used to determine many of the assemblies on your lift truck (power, tire type, mast type). The complete truck model and serial number are stamped into the nameplate. See Identification of Truck Serial Number on Page viii for further information.

SECTIONS 1 GENERAL TRUCK 2 ELECTRICAL SYSTEM 3 DRIVE UNIT 4 STEERING SYSTEM 5 CASTER, LOAD WHEEL AND BRAKE SYSTEM 6 HYDRAULIC SYSTEM 7 LIFTING MECHANISM 8 OPTIONS 9 NUMERICAL INDEX 10 USER SUPPORT INFORMATION This Parts Manual is divided into 10 major sections which are listed above. Quick reference to these sections can be made by placing the right thumb on the tab of the desired section, bending the book back and thumbing the pages to the corresponding tab.

GENERAL INFORMATION ALPHABETICAL INDEX DESCRIPTION PAGE NO. A ABBREVIATIONS QUICK REFERENCE SHEET .................................................................................................... v ALPHABETICAL INDEX............................................................................................................................................ i B BACK UP ALARM .............................................................................................................................................. 8-16 BATTERY CONNECTOR ................................................................................................................................... 2-24 BRAKE ASSEMBLY ............................................................................................................................................. 5-6 BRAKE PEDAL AND OPERATOR SENSING SWITCH ....................................................................................... 5-4 C CARRIAGE SCISSOR 24 IN. REACH ............................................................................................................................................. 7-24 42 IN. REACH ............................................................................................................................................. 7-26 STRADDLE NS040-050AE ............................................................................................................................................. 7-21 CASTER ASSEMBLY ......................................................................................................................................... 5-10 CHAINS, PINS, AND ANCHORS TWO STAGE LIMITED FREE-LIFT................................................................................................................. 7-38 CHAINS, PINS, SHEAVES, AND ANCHORS THREE STAGE FULL FREE-LIFT NR 035 AE, NR 040 AE, NR 045 AE, NDR 030 AE ...................................................................................... 7-6 CONTACTOR PANEL ASSEMBLY "E" CONSTRUCTION ....................................................................................................................................... 2-6 "EE" CONSTRUCTION..................................................................................................................................... 2-8 D DECAL AND PLATE LOCATION ........................................................................................................................ 1-10 DOUBLE REACH HYDRAULICS ....................................................................................................................... 6-18 DRIVE BRAKE ASSEMBLY ................................................................................................................................. 5-2 DRIVE MOTOR ASSEMBLY S/N C815N-02259Z⇒ (C815), S/N C816N-01524Z⇒ (C816) ........................................................................ 2-22 ⇒S/N C815N-02259Z (C815), ⇒S/N C816N-01524Z (C816) ........................................................................ 2-20 DRIVE UNIT ARRANGEMENT ............................................................................................................................ 3-2 DRIVE UNIT ASSEMBLY S/N C815N-02259Z⇒ (C815), S/N C816N-01524Z⇒ (C816) .......................................................................... 3-6 ⇒S/N C815N-02259Z (C815), ⇒S/N C816N-01524Z (C816) .......................................................................... 3-4 DRIVE UNIT COMPARTMENT FAN ASSEMBLY............................................................................................... 8-10 E ELECTRICAL ARRANGEMENT .......................................................................................................................... 2-2 ELECTRICAL COMPONENTS........................................................................................................................... 2-26 EXTEND CYLINDER ASSEMBLY ...................................................................................................................... 7-28 i

GENERAL INFORMATION DESCRIPTION PAGE NO. F FORK CARRIAGE ASSEMBLY .......................................................................................................................... 7-48 THREE STAGE FULL FREE-LIFT NS 040/050 AF ............................................................................................................................................ 7-16 FORKS HOOK TYPE ⇒D/B 10/2001 ............................................................................................................................................. 1-16 D/B 10/2002⇒............................................................................................................................................. 1-14 FREE LIFT CYLINDER ASSEMBLY THREE STAGE FULL FREE-LIFT NR 035 AE, NR 040 AE, NR 045 AE, NDR 030 AE .................................................................................... 7-12 G GEAR PUMP ...................................................................................................................................................... 4-16 GENERAL TRUCK NR 035-045 AE AND NDR 030 AE................................................................................................................... 1-2 NS 040/050 AF ................................................................................................................................................. 1-4 H HOOD AND COVERS .......................................................................................................................................... 1-6 HOOK TYPE CARRIAGE OPTION NR 035-045 AE AND NDR 030 AE................................................................................................................... 8-6 HOSE AND WIRE TAKE-UP TWO AND THREE STAGE FULL FREE-LIFT NR 035-045 AE AND NDR 030 AE ............................................................................................................. 7-30 HOSE TAKE-UP GROUP STRADDLE NS040-050AE ............................................................................................................................................. 7-50 HOW TO FIND THE DESIRED PART NUMBER.................................................................................................... vii HOW TO USE THE ILLUSTRATED PARTS MANUAL ........................................................................................... vii HYDRAULIC CONTROL VALVE D/B 05/2002⇒ .................................................................................................................................................. 6-8 ⇒D/B 05/2002 .................................................................................................................................................. 6-6 HYDRAULIC MOTOR ......................................................................................................................................... 6-14 HYDRAULIC PUMP AND MOTOR ..................................................................................................................... 6-10 HYDRAULIC PUMP ASSEMBLY........................................................................................................................ 6-12 HYDRAULIC SYSTEM ......................................................................................................................................... 6-2 HYDRAULIC TANK ASSEMBLY ......................................................................................................................... 6-16 I IDENTIFICATION OF ATTACHMENT AND SIDE-SHIFT CARRIAGE SERIAL NUMBERS..................................... x IDENTIFICATION OF MAST SERIAL NUMBER ..................................................................................................... ix IDENTIFICATION OF TRUCK SERIAL NUMBER ................................................................................................. viii INNER CARRIAGE............................................................................................................................................. 7-18 INTEGRAL SIDE-SHIFT ASSEMBLY................................................................................................................. 7-34 INTEGRAL TILT ASSEMBLY.............................................................................................................................. 7-32 ii

GENERAL INFORMATION DESCRIPTION PAGE NO. L LIFT AND FREE LIFT CYLINDER CONNECTING GROUP THREE STAGE FULL FREE-LIFT .................................................................................................................. 7-10 LIFT AND FREE LIFT CYLINDER INSTALLATION THREE STAGE FULL FREE-LIFT .................................................................................................................... 7-8 LIFT CYLINDER ASSEMBLY THREE STAGE FULL FREE-LIFT NR 035 AE, NR 040 AE, NR 045 AE, NDR 030 AE ...................................................................................... 7-4 TWO STAGE FULL FREE-LIFT NR 035 AE, NR 040 AE, NR 045 AE .......................................................................................................... 7-42 LIFT CYLINDER CONNECTING GROUP.......................................................................................................... 7-44 LIFT CYLINDER INSTALLATION ....................................................................................................................... 7-40 LIFT LIMIT SWITCH........................................................................................................................................... 7-46 THREE STAGE FULL FREE-LIFT .................................................................................................................. 7-14 LIFT PUMP CONTACTOR.................................................................................................................................. 2-18 LIGHT AND FAN ASSEMBLY............................................................................................................................... 8-8 LOAD BACKREST ............................................................................................................................................. 1-12 M MAST MOUNTED HEADLIGHTS ...................................................................................................................... 8-12 MASTER CYLINDER ........................................................................................................................................... 5-8 MASTER PART SHEET CROSS-REFERENCE ..................................................................................................... xi MULTI-FUNCTION CONTROL HANDLE C815 ............................................................................................................................................................... 2-10 C816 ............................................................................................................................................................... 2-12 P POWER STEER ARRANGEMENT S/N C815N-02259Z⇒, S/N C816N-01524Z⇒.................................................................................................. 4-4 ⇒S/N C815N-02259Z, ⇒S/N C816N-01524Z.................................................................................................. 4-2 POWER STEER CONTACTOR .......................................................................................................................... 2-14 R REAR WORKING LIGHT ................................................................................................................................... 8-14 S SIDE-SHIFT CYLINDER ASSEMBLY NS 040/050 AF ................................................................................................................................................. 8-4 SIDE-SHIFT HYDRAULIC HOOKUP SHEET 1 OF 2 .................................................................................................................................................. 8-2 SHEET 2 OF 2 .................................................................................................................................................. 8-3 SINGLE LOAD WHEEL ...................................................................................................................................... 5-14 SINGLE REACH HYDRAULICS ......................................................................................................................... 6-20 SLAVE CYLINDER ............................................................................................................................................... 5-7 STEER CONTROL UNIT S/N C815N-02259Z⇒, S/N C816N-01524Z⇒.................................................................................................. 4-8 ⇒S/N C815N-02259Z, ⇒S/N C816N-01524Z.................................................................................................. 4-6 STEER MOTOR HYDRAULIC S/N C815N-2259Z⇒, S/N C816N-1524Z⇒ ................................................................................................ 4-12 iii

GENERAL INFORMATION DESCRIPTION PAGE NO. S (continued) ⇒S/N C815N-2259Z, ⇒S/N C816N-1524Z ................................................................................................ 4-10 STEER MOTOR ASSEMBLY "E" CONSTRUCTION ..................................................................................................................................... 4-18 "EE" CONSTRUCTION ................................................................................................................................... 4-20 STEER PUMP AND MOTOR ............................................................................................................................. 4-14 T TANDEM LOAD WHEEL .................................................................................................................................... 5-12 TRACTION CONTACTOR .................................................................................................................................. 2-16 U UPRIGHTS THREE STAGE FULL FREE-LIFT NR 035 AE, NR 040 AE, NR 045 AE, NDR 030 AE ...................................................................................... 7-2 TWO STAGE LIMITED AND STRADDLE NR 035 AE, NR 040 AE, NR 045 AE, NS040-050AE ................................................................................. 7-36 iv

GENERAL INFORMATION ABBREVIATIONS QUICK REFERENCE SHEET Listed below are abbreviations used in parts manuals to denote the following expressions: TERM DEFINITION TERM DEFINITION Amp Amperes AR As Required BDI Battery Discharge Indicators BWI Brush Wear Indicator CE Communicator End CRE Corrosive Environment D/B Date Break dbA Decibel "A" Scale DE Drive End ECM Electronic Control Module ECN Engineering Change Notice EEPROM Electrically Erasable Programmable Read Only Memory EPROM Electrically Programmable Read Only Memory FRE Freezer Environment in. inches LPG Liquefied Petroleum Gas MAP Manifold Absolute Pressure mm millimeters MSTS Microprocessor Spark Timing System NPT National Pipe Threads O/S Oversize PTO Power Take Off RPM Revolutions per Minute S/N Serial Number TMM Truck Management Module UL Type D Diesel-Powered Safety Rating UL Type DS Diesel-Powered Safety Rating UL Type E Battery-Powered Safety Rating UL Type EE Battery-Powered Safety Rating UL Type ES Battery-Powered Safety Rating UL Type G Gasoline-Powered Safety Rating UL Type GS Gasoline-Powered Safety Rating UL Type LP Gas-Powered Safety Rating UL Type LPS LP Gas-Powered Safety Rating U/S Undersize UL Underwriters Laboratory V Volts v

GENERAL INFORMATION HOW TO USE THE ILLUSTRATED PARTS MANUAL This parts manual describes and illustrates assemblies, subassemblies, and detail parts needed for service replacement. The different constructions are indicated by keys and footnotes. The callouts correspond to descriptions found on the next page. vi

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Yale Electric Reach Truck: NDR030AE, NR035AE, NR040AE, NR045AE [C815], NS040AF, NS050AF [C816] Service Manual

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