Yale (C829, A861) NR 030, NR 045, NR CA, NR GA, NDR 030, NDR 045, NDR CA, NDR GA Lift Truck Service Repair Manual Repair and Maintenance Manual

MAINTENANCE MANUAL For Models NR 035/040/045 AC 3,500-4,000-4,500 LBS. CAPACITY NR 035/045 BC 3,500-4,500 LBS. CAPACITY NDR 030 AC/BC 3,000 LB. CAPACITY NS 040/050 AD 4,000-5,000 LBS. CAPACITY For Service & Parts Contact Yale Materials Handling Corp. 1400 Sullivan Drive Caller No. 12011 Greenville, NC 27834-2011 Authorized Dealer 1636 ® September 1 996

Yale Industrial Trucks EXPLANATION OF MODEL CODE NARROW AISLE REACH - RATED CAPACITY 030 - 3,000 Lbs. 035 - 3,500 Lbs. 040 - 4,000 Lbs. 045 - 4,500 Lbs. 050 -5,000 Lbs. - SPECIAL DESIGNATION A, B - As Assigned DESIGN SERIES A, B, C, D etc. MANUFACTURING SOURCE N - North America DOUBLE REACH FULLY LOWERED MAST HEIGHT Measured in Inches STRADDLE MAST TYPE V -Simplex E -Triplex - CONTROL T -Transistor - VOLTAGE 24, 36 - BATTERY COMPARTMENT 035 089 S - 12.5 Small - (Small Chassis) M -14.6 Medium -(Small Chassis) L - 16.6 Large - (Small Chassis) M -18.8 Medium -(Large Chassis) L - 21.1 Large - (Large Chassis) To verify that this manual is correct for this truck compare the model code, as explained above, with the nameplate on the truck. Refer to Table of Contents for nameplate location and information. If the model code in this manual does not agree with the information on the nameplate contact your Yale industrial truck dealer. SPECIAL NOTE This Maintenance Manual contains complete and accurate information available at the time of publication for the components and systems listed. Yale Materials Handling Corporation reserves the right to make changes to its product at any time and the possibility exists that later changes are not included in this manual. If your lift truck is equipped with special options that are not covered in this Maintenance Manual, you should contact your local Yale industrial truck dealer for additional information.

Y&fe Industrial Trucks This Maintenance Manual is divided into major sections which are listed on this page. Quick reference to these sections can be made by placing the right thumb on the tab of the desired section, bendingthe book back and thumbing the pages to the corresponding tab. SECTIONS 1 OPERATING INSTRUCTIONS I ÿ 2 GENERAL TRUCK AND LUBRICATION SCHEDULE 3 ELECTRICAL SYSTEM ÿ 4 DRIVE UNIT ÿ ÿ 5 BRAKE SYSTEM I I 6 STEERING SYSTEM 7 HYDRAULIC SYSTEM I 8 MAST AND REACH ASSEMBLY I 9 BATTERY AND CHARGING SYSTEM ÿ 10 USER SUPPORT INFORMATION ÿ 11 ALPHABETICAL INDEX

Yale Industrial Trucks SECTION 1 OPERATING INSTRUCTIONS

Yale Industrial Trucks SECTION 1 - CONTENTS INTRODUCTION DESCRIPTION PAGE NUMBER OPERATING INSTRUCTIONS-GENERAL 1-1 SAFETY LABELS 1-2 OPERATOR PRE-CHECKS AND INSPECTION 1-2 OPERATING PROCEDURE-GENERAL 1-3 SHUT DOWN PROCEDURE 1-3 FORKADJUSTMENT 1-3 SAFETY AND OPERATIONAL CHECKLIST 1-4 MODEL AND OPERATING INFORMATION 1-6 SAFE MAINTENANCE PROCEDURES 1-9 MOVING A DISABLED LIFT TRUCK 1-10 HOW TO TOW A LIFT TRUCK 1-10 HOW TO PUTA LIFT TRUCK ON BLOCKS 1-10 HOW TO RAISE THE LOAD WHEELS 1-11 HOW TO RAISE THE DRIVE/STEER TIRE AND CASTER WHEELS ...... 1-11 PRECAUTIONS FOR TRUCKS INSTORAGE 1-11 PRECAUTIONS FOR BATTERIES INSTORAGE 1-12

Yale Industrial Trucks OPERATING INSTRUCTIONS-GENERAL Before attempting to operate this truck, carefully read and understand these operating procedures. Make sure the truck is in proper operating condition. Visually inspect the entire truck for any damage that may have occurred during shipment. NOTE: Throughout this manual the terms right, left, front and rear relate to the viewpoint of an operator riding on the truck with the forks trailing. Familiarize yourself with the information contained on the nameplate which is located in the operator's compartment. Information on this nameplate is shown in Figure 1-1 and as follows: A. Serial Number This is an identification number assigned to this particular truck and should be used when ordering service parts or when requesting any information from your Yale industrial truck dealer. The serial number is a six digit number preceded by a letter and is stamped on the lift truck frame and on the nameplate. B. Model Code The model number and the serial number should be used when requesting information. An explanation of the model code is located on Page B of this manual. OPERATING INSTRUCTIONS C. Truck Weight This is the approximate weight of the truck without a load on the forks. This weight plus the weight of the load to be moved must be considered when operating on elevated floors or elevators. D. Capacity Rating This rating shows the maximum load capacity of this truck. Personal injury and damage to the truck can occur if the capacity rating is exceeded. This truck meets all applicable mandatory requirements of ANSI B56.1 Safety Standard for Powered Industrial Trucks at the time of manufacture. In addition, these trucks are classified by Underwriters' Laboratories, Inc. and/or approved by Factory Mutual Engineering Corporation for the type designation. Consult UL Index of Classified Products and FM Approval Guide. No additions, omissions or modifications should be made that will affect compliance to the previously stated requirements or in any way minimize the effectiveness of the safety devices. Safety and informational labels are located in conspicuous locations on this truck and should be strictly followed. Check the nameplate of each truck before operation. These safety and informational labels must be replaced immediately if missing or defaced. Labels will vary with type of truck and equipment installed. Refer to the Parts Manual for part number and location for all labels. NOTICE TO USER The U.S.A. Occupational Safety and Health Act of 1970 and other national safety codes require a new plate if this unit is equipped other than as stated on plate. Obtain the correct plate from your authorized dealer. If a truck is shipped incomplete from the factory, the nameplate will be covered by the label shown above. Do not operate the lift truck until you obtain a complete nameplate from your Yale industrial truck dealer. a. 1 i Yak> Model no. ÿTruck Serial no. Battary Type Vtofts Max. A.H. I f I Battery Size InX inx In Thick Weight Less Battery to ÿTruck Weight With Ban to Allowable Bait. Wt Range to to Outrigger Width Inches Wheelbase Inches Articulation: Drive Side Inches/ Caster Side Inches *o/-xx t»mC Low Canto. J? cw low Cantor M> mft I A WARNING THAWED OPERATORS ANO MECHANICS ONLY noetwiwio totwo oewaone w DO NOT OVERLOAD WUh MaownomMnwtnl No towm 11, r1? O as—*" rl i gsa- Capacities and cautions contained on this nameplate must be strictly followed. Figure 1-1 - Nameplate Information 1-1

Yale Industrial Trucks SAFETY LABELS A definition of the safety labels used on the motorized lift trucks is listed below. /j\ DANGER DANGER: Identified by a Red Label, immediate hazards which WILL result in severe personal injury or death. /j\ WARNING WARNING: Identified by a Orange Label, hazards or unsafe practices which MAY result in personal injury or death. /K CAUTION CAUTION: Identified by a Yellow Label, hazards or unsafe practices which may result in minor personal injury, product or property damage. THE READER MAYFINDANY OR ALL OF THE FOLLOWING LABELS USED IN THIS PUBLICATION. AN UNDERSTAND¬ ING OF THEIR USE, AS GIVEN BELOW WILL AID THE READER. NOTE An advisory procedure, practice, condition, etc., which is essential to emphasize. /K CAUTION Directs attention to hazards or unsafe practices which may result in minor personal injury, product or property damage if the proper precautions are not taken. /j\ WARNING Directs attention to unsafe practices which could result in personal injury or death if proper precautions are not taken. /j\ DANGER Directs attention to unsafe practices and/or existing hazards which WILL result in severe personal injury or death if proper precautions are not taken. OPERATING INSTRUCTIONS OPERATOR PRE-CHECKS AND INSPECTION Before each shift, every 8 hours or before beginning truck operation it is the operator's responsibility to carry out the following checks and inspections. Do not operate the truck if it is in need of repair, if it is in an unsafe condition, or might contribute to an unsafe condition. Remove the key and report the condition to the proper authority. If the truck becomes unsafe in any way while you are operating it, STOP operating the lift truck and report the matter immediately to the proper authority. Basic maintenance information and the Recommended Schedule of Maintenance are in the Operating Manual, Part Number 5198158-03, located in the document holder on the mast screen. Also refer to Section 2 of this manual. 1 . Make sure overhead guard, load backrest extension, mast screens and all other safety devices are attached. 2. Make sure all capacity, safety and informational plates or labels are attached. This truck is not considered safe to use without a legible, properly filled out nameplate. Contact Yale Materials Handling Corporation or your local dealer for Yale industrial trucks if the nameplate is not present and legible. See parts manual for label page with label and plate locations. 3. Inspect truck for any damage that might have occurred during the previous shift. 4. Inspect truck for any signs of external leaking of the battery, steering system or hydraulic system. 5. Check hydraulic hoses for leaking, chafing, cuts or reinforcement showing through the outside of the hose. 6. Make sure chains are not damaged or kinked. Check for excess slack or mistracking on the sheaves. 7. Make sure all latches are adjusted (if necessary) and fastened. 8. Operate brake, hydraulic controls, lift, tilt and auxiliary and steering. Make sure all controls operate correctly and return to their proper positions. See section on Operating Controls for detailed descriptions. 9. Inspect condition of wheels and tires. 10. Inspect forks for damage. Make sure they are correctly attached and locking clips are in their proper position. 11. Test horn, lights, gauges and meters. Make sure they work correctly. 1-2

Yale Industrial Trucks 12. Make sure any unusual noises are investigated immediately. OPERATING PROCEDURE-GENERAL ÿ Read and understand the Operating Manual supplied with the lift truck. Notify your supervisor if the manual is not available. ÿ Keep hands, feet and other parts of your body inside the designated operator's compartment. Parts of your body outside the truck can be injured when passing obstructions. ÿ Do not permit passengers to ride on the truck. ÿ Observe and comply with instructions concerning floor loadings. Know the weight of your truck and load combined. Truck weight information is located on the nameplate. ÿ Travel with the load lowered and where possible, tilted back. Do not elevate the load except during stacking. ÿ The operator can change the direction of travel while the lift truck is moving, by moving the direction control lever in the opposite direction. The truck will come to a stop and then accelerate in the opposite direction, unless the control lever is released. This is called plugging. ÿ Look in the direction of travel and keep a clear view of the path of travel. ÿ If visibility is impaired by the load, operate truck with the forks trailing and always look in the direction of travel. ÿ Start, stop, travel, steer and brake smoothly. Slow down for turns and on uneven or slippery surfaces that could cause truck to overturn or slide. ÿ Watch clearances around forks. The driver must be aware that the forks can sometimes extend beyondthe load. This may cause the forks to hit an object or lift another load. ÿ Watch out for any obstructions, especially those overhead. Check clearances. ÿ Do not run over objects on the roadway surface as truck stability and steering may be adversely affected. ÿ When approaching cross aisles, slow down, sound horn and keep to the right side of aisle. ÿ Operate truck under all conditions at a speed that will permit it to be brought to a stop in a safe manner. ÿ Narrow Aisle trucks are designed for use on smooth, hard floors with minimal grades. OPERATING INSTRUCTIONS ÿ Operate a loaded truck with the load upgrade. Operate an unloaded truck with the lifting mechanism downgrade. ÿ Do not push loads with the truck. ÿ Watch out for pedestrians at all times. Do not drive up to anyone standing in front of an object. ÿ Observe all traffic regulations, including authorized plant speed limits. Under normal traffic conditions, keep to the right. Maintain a safe distance from the truck ahead (approximately three truck lengths), and keep the truck under control at all times. ÿ Yale lift trucks are not intended for use on public roads. ÿ When leaving truck unattended, lower the lifting mechanism, shut off power and remove key. Chock wheels if truck is parked on an incline. ÿ Report all accidents involving personnel, building structures and equipment to the proper authority. ÿ Check all gauges and indicator lights for correct operation. Frequent reading of the instrument panel should become a habit. ÿ Avoid any abrupt moves. Be a professional. "HANDLE WITH CARE." ÿ Follow the Recommended Schedules of Maintenance. Maintain your lift truck for dependable and economical operation. SHUT DOWN PROCEDURE When leaving truck unattended, fully lower forks, shut off power, set brake, set coast control to off (when equipped), neutralize controls and remove key. If you park the truck on an incline, chock the wheels. FORK ADJUSTMENT Forks should be spaced as far apart on the fork carriage as the load being moved will allow. Both forks should always be the same distance from the center of the fork carriage. Check for the presence and condition of studs at each end of the carriage upper fork clip slide. If studs are damaged or missing they should be repaired or replaced before the forks are adjusted. 1-3

Yale IndustrialTrucks To adjust the forks, raise them a few inches off the floor. Lift up on the keeper pin and slide the forks along the carriage by pushing them away from you. Do not pull the forks toward you. When the forks are set to the desired position, make sure the keeper pin is down in a slot on the top of the fork carriage plate. SAFETY AND OPERATIONAL CHECK LIST A "Daily Check Lisf similar to the one shown on the next page should be usedevery day before operatingthe truck. The check lists are available in tablet form with 50 sheets per tablet and OPERATING INSTRUCTIONS can be obtained from your local Yale Industrial Truck Dealer for a nominal fee. Both this manual and the Operating Manual contain the Recommended Schedules of Maintenance which should be used as a guide along with the Lubrication Instructions. A professional operator should also be familiar with the information contained in the American National Safety Standard for Powered Trucks - ANSI B56.1, Part II. CD Figure 1-2 - Typical Narrow Aisle Electric Lift Truck 1-4

Yale Industrial Trucks OPERATING INSTRUCTIONS NOTE: This Daily Check List is available for the Operator. Some items on this list may not be applicable to your truck. This convenient check list is in tablet form and can be ordered through your Yale Industrial Truck Dealer. Form Number 944-6418-A. Yale Industrial Trucks Record of Fluid Added Daily pre-shift inspection is an OSHA requirement. We recommend that you document that these inspections have been made. _ Operator's Daily Check List Electric Truck Date Operator Battery Water Truck Number Model Number Hydraulic Oil Department Serial Number Shift Drive Hour Hoist Hour Meter Reading Meter Reading SAFETY AND OPERATIONAL CHECKS (Prior to each shift) Have a qualified mechanic correct all problems (O.K.*-') Need Maintenance Leaks - Hydraulic Oil, Battery Tires - Condition and Pressure Forks, Top Clip Retaining Pin and Heel - Check Condition Load Backrest/Extension - Securely Attached Hydraulic Hoses, Mast Chains and Stops - Check Visually Finger Guards - Attached Overhead Guard - Attached Safety Warnings - Attached (Refer to Parts Manual for Location) Internal Checks: Battery - Check Water/Electrolyte Level and Charge Hydraulic Fluid Level - Check Level Drive Unit Fluid Level - Check Level Operator's Compartment: Operating Manual - in Container Nameplate - Attached and information matches model, serial number and attachments Battery Restraint System - Adjusted and Securely Fastened Seat Belt, Buckle and Retractors - Functioning Smoothly Brake Fluid - Check Level Controls (Turn Truck On) Unusual Noises Must Be Investigated Immediately: Accelerator Linkage - Functioning Smoothly Parking Brake - Functioning Sen/ice Brake - Functioning Smoothly Steering Operation - Functioning Smoothly Drive Control - Forward/Reverse - Functioning Smoothly Tilt Control - Forward and Back - Functioning Smoothly Hoist and Lowering Control - Functioning Smoothly Attachment Control - Operation Horn and Lights - Functioning Gauges: Hour Meter/Battery Discharge Indicator - Functioning Instrument Monitors - Functioning Form 944-6418-A (5/93) © Copyright 1993 Yale Materials Handling Corporation 1-5

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Yale (C829, A861) NR 030, NR 045, NR CA, NR GA, NDR 030, NDR 045, NDR CA, NDR GA Lift Truck Service Repair Manual Repair and Maintenance Manual

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