This document is a maintenance and repair manual for Yale forklifts, specifically covering diagrams for models NR035-040DB, NDR030DB [B295]; NDR035EB, NR045EB [D861]; and NDR030EB, NR035-040EB [E815]. It provides detailed schematic and wiring diagrams, as well as hydraulic schematics, essential for technicians performing service and troubleshooting on these electric lift trucks.
Function Description:
The manual serves as a comprehensive guide for understanding the electrical and hydraulic systems of the specified Yale forklift models. It details the interconnections of various components, allowing technicians to diagnose faults, perform repairs, and ensure proper functioning of the equipment. The diagrams illustrate the flow of power, signals, and hydraulic fluid, which are critical for the operation of the forklift's core functions such as traction, steering, lifting, and auxiliary movements.
Important Technical Specifications (Derived from diagrams and notes):
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Electrical System:
- Battery Voltage: The diagrams indicate a 36V system with options for 12V and 24V regulators, suggesting a primary 36V battery for main power.
- Fuses: Integrated Fuse Board (IFB) is a central component, with various fuses protecting different circuits (e.g., 10A for logic power out, 110A for E-Stop, 0.3A for PTC-3).
- CAN Bus: Utilizes a Controller Area Network (CAN bus) for communication between modules. CAN bus node LO wire is green (500), and CAN bus node HI wire is yellow (501). All 900 and 901 wires must be twisted together for proper CAN bus operation.
- Motor Types: Includes diagrams for Traction Motor (AC), Hydraulic Motor (AC), and Auxiliary Motor (AC).
- Sensors: Various sensors are depicted, including Impact Sensor, Height Sensor, Tilt Sensor, Proximity Sensors (e.g., Reach Position Sensor, Hot Prox Sensor, Caster Center Proximity Sensor), Temperature Sensors (e.g., Traction Motor Temp, Pump Motor Temp, Inside Thermo, Outside Thermo), and Operator Presence Sensors (e.g., Foot Switch, Operator Sensor Switch).
- Controllers: Features Traction Controller, Pump Controller, Steer Controller, and EPS-ACO (Electric Power Steering - AC) Main Controller and Caster Controller.
- Connectors and Terminals: Extensive use of standardized connectors (e.g., CPS, CPP, CRP, CRS) and terminals (e.g., TS, TP) for modularity and ease of service.
- Wiring Colors: Standardized wire color abbreviations are provided (e.g., BLK for Black, RED for Red, GRN for Green, YEL for Yellow, BLU for Blue). Striped wires are indicated by primary/stripe (e.g., BLU/WHD).
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Hydraulic System:
- Pressure Relief Valves: Diagrams show pressure relief valves set at 2500 PSI and 3000 PSI, indicating different pressure requirements for various hydraulic functions.
- Pumps and Motors: Includes a Hoist Pump and Motor Assembly and an Auxiliary Pump and Motor Assembly.
- Cylinders: Features Reach Cylinders (LH and RH), Tilt Cylinder, and Sideshift Cylinder (optional).
- Valves: Depicts various solenoid valves (SV1, SV2) for controlling hydraulic functions like extend/retract, sideshift, and tilt. Also includes a Front Carriage Assembly Counter Balance Selector Valve and a Hydraulic Proportional Valve.
- Flow Control: Shows a 25:1 flow control for certain hydraulic circuits.
Usage Features (Implied from diagrams):
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Operator Controls:
- Key Switch: Includes positions for OFF, ACC (Accessory), and IGN (Ignition)/ST (Start).
- Steering: Features a Steer Tiller and options for Steered Caster. Steering is set for straight travel in the normal position.
- Handle Controls: Fore/Aft Handle and Side Stance Handle options are shown, with controls for horn, enable, and throttle.
- Work Lights: Options for Rear Work Light, Left Front Work Light, Right Front Work Light, and Right Rear Work Light.
- Strobe Light: An optional strobe light is available.
- Backup Alarm: An optional backup alarm is included.
- Compartment Fan: An operator compartment fan is an option.
- Display: A dash display unit provides operational information.
- Video Camera and Monitor: An optional video camera and monitor system is available.
- Impact Sensor Module: An optional impact sensor module is present, with different configurations for side stance and fore/aft setups.
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Environmental Features:
- Heater Options: Includes options for Freezer Heater and Arctic/Freezer Heater, indicating suitability for cold environments.
- Thermostats: Inside and Outside Thermostats are part of the heater control system.
Maintenance Features (Explicitly stated or implied from safety precautions and diagrams):
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Safety Precautions:
- Disconnect Battery: Emphasizes disconnecting the battery connector before any maintenance or repair on electric lift trucks.
- Lifting Procedures: Instructions for safe lifting of parts and assemblies using appropriate mechanisms and ensuring balanced loads.
- Personal Protective Equipment: Mandates wearing safety glasses.
- Blocking: Use correct blocks to prevent the unit from rolling or falling.
- Cleanliness: Maintain a clean unit and working area.
- Tools: Use correct and clean tools.
- Approved Parts: Use only Yale-approved replacement parts that meet original equipment manufacturer specifications.
- Fasteners: Ensure all nuts, bolts, snap rings, and other fastening devices are removed before applying force to remove parts.
- DO NOT OPERATE Tag: Always fasten a "DO NOT OPERATE" tag to the controls when making repairs.
- Flammable Materials: Specific precautions for handling gasoline, LPG, CNG, and Diesel fuel, and for charging batteries (flammable gas, keep fire/sparks away, ventilate area).
- WARNING/CAUTION Notes: Adherence to WARNING (death or serious injury) and CAUTION (minor injury and property damage) notes in the instructions.
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Troubleshooting and Diagnostics:
- Diagrams: Detailed schematic/wiring diagrams and hydraulic schematics are provided for systematic troubleshooting.
- CAN Bus: The CAN bus system facilitates communication between modules, aiding in diagnostics.
- Diagnostic Connector: A dedicated diagnostic connector (CP5028) is present for connecting diagnostic tools.
- Termination Resistor: Instructions for connecting a termination resistor to the CAN bus for retail truck configurations.
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Component Accessibility: The modular nature of the wiring and hydraulic systems, with numerous connectors and clearly labeled components, suggests design for ease of access and replacement during maintenance.
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Regular Updates: Service Manuals are updated regularly, and technicians are advised to check with authorized Yale dealers for the latest technical service information, indicating a commitment to continuous improvement and support.
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