PDF Service Manual Yale NDR030GB NR045GB Forklift - 2 MB
This service and maintenance manual is the complete guide for the Yale NDR030GB and NR045GB (B861 series) reach trucks.
It provides detailed technical information for troubleshooting, repairing, and maintaining your equipment.
The manual includes wiring diagrams, hydraulic schematics, and step-by-step repair procedures.
It is an indispensable tool for any technician responsible for keeping these Yale forklifts in optimal working order.
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--- Page 1 ---
Maintenance
%5$.( 6<67(0
NDR030GB, NR045GB [B861]
PART NO. 524164466 1800 YRM 983
--- Page 4 ---
8000 YRM 972 Battery Size Specifications
Sideshift Cylinder Stroke 180 mm (7.09 in.)
Tilt Cylinder Stroke 36 mm (1.4 in.)
Fork Tilt Angle
Down 3 degrees
Up 4 degrees
Battery Size Specifications
Minimum Battery Size*
Weight
Model Volts Compartment Size Minimum/Maximum
Length Γ Width Length Width Minimum Maximum
986 Γ 318 mm (38.8 986 mm 311.1 mm 568 kg 863 kg
NR035AE, Γ 12.5 in.) (38.8 in.) (12.25 in.) (1250 lb) (1900 lb)
NR040AE,
986 Γ 371 mm (38.8 986 mm 365 mm 681 kg 953 kg
NDR030AE, 24
Γ 14.6 in.) (38.8 in.) (14.38 in.) (1500 lb) (2100 lb)
NS040/
050AF 986 Γ 422 mm (38.8 986 mm 416 mm 726 kg 1033 kg
Γ 16.6 in.) (38.8 in.) (16.38 in.) (1600 lb) (2275 lb)
NR045CB, 986 Γ 371 mm (38.8 986 mm 365 mm 704 kg 953 kg
NDR030CB, Γ 14.6 in.) (38.8 in.) (14.38 in.) (1550 lb) (2100 lb)
36
NR045GB, 986 Γ 422 mm (38.8 986 mm 416 mm 840 kg 1090 kg
NDR030GB Γ 16.6 in.) (38.8 in.) (16.38 in.) (1850 lb) (2400 lb)
986 Γ 422 mm (38.8 986 mm 416 mm 840 kg 1090 kg
Γ 16.6 in.) (38.8 in.) (16.38 in.) (1850 lb) (2400 lb)
NR045CB,
NDR030CB, 986 Γ 478 mm (38.8 986 mm 473 mm 999 kg 1294 kg
36
NR045GB, Γ 18.8 in.) (38.8 in.) (18.62 in.) (2200 lb) (2850 lb)
NDR030GB
986 Γ 536 mm (38.8 986 mm 530 mm 1135 kg 1362 kg
Γ 21.1 in.) (38.8 in.) (20.88 in.) (2500 lb) (3000 lb)
Compartment width is across the width of the lift truck. Battery length installed across lift truck, battery width
installed front to back.
*Maximum height for all batteries is 787 mm (31.0 in.).
WARNING
The battery must fit the battery compartment so the battery restraint system will operate correctly. Use the
specified spacers to prevent the battery from moving more than 13 mm (0.5 in.) in any horizontal direction.
NOTE: Maximum tolerances are +0 and β13 mm (+0 and β0.5 in.) for the size of the battery compartment. The
battery specification chart shows the maximum size tolerances that will permit the battery to still fit into the battery
compartment.
5
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620 YRM 294 Brush and Commutator Inspection
General
This section describes disassembly and assembly, the traction motors is fastened to the armature and can
brush installation, inspection, and checks for mal- be removed from the armature. The cooling fan can be
functions of DC motors. Inspect the commutator and removed during disassembly of the traction motor.
brushes every 350 hours of operation. The commu-
tator is the rotating electric connection between the The cooling fan in the hydraulic pump motors can be a
armature and the electric power supplied by the bat- press fit on the armature shaft and is not easily removed
tery. Brushes made of carbon compounds slide on during disassembly of the motor. The armature and
the rotating commutator and are the path for electricity cooling fan must be removed from the drive end of the
from the battery to the commutator and the armature. motor during disassembly.
The maintenance of the commutator and the brushes
The assembly and disassembly of the motor used for
is important to the good operation of a DC motor.
the power steering pump is described in the Steering
Traction motors and hydraulic pump motors are similar System section. This motor is a permanent magnet mo-
in design. The hydraulic pump motors are smaller than tor.
the traction motors, but the disassembly and mainte-
nance of these motors are similar. The cooling fan in
Brush and Commutator Inspection
HYDRAULIC PUMP MOTOR AND the battery, either raise the hood panels or unfasten the
TRACTION MOTOR floor plate, depending on which motor needs to be ac-
cessed.
NOTE: The brushes and commutator can be inspected,
the brushes can be replaced, and Stoning the Commu- 2. Remove battery. See How to Remove Battery
tator can be done with the motor installed in the truck. in the Operating Manual or the Periodic Mainte-
nance YRM section for your lift truck. Remove ac-
NOTE: Inspect the brushes and commutator every 350 cess plate to motors. If the battery in your lift truck
hours for best operation and to prevent motor damage. does not need removal for access to the motors, go
The hydraulic pump motor normally has more start cy- to Step 3.
cles than other motors, so it can have more wear and
possible damage.
NOTE: The following procedure is for inspecting the
brushes and commutator with the motor installed in the
lift truck. The same inspections can be done with the
motor removed. If the motor is removed, start at Step 3.
1. To rotate the commutator of the traction motor with-
out moving the truck, the drive wheels must be
raised. See Figure 1. Raise drive wheels so com-
mutator of the traction motor can be rotated without
moving lift truck. See How To Raise Drive Wheels
in the Operating Manual or the Periodic Mainte-
nance YRM section for your lift truck.
1. ARMATURE 2. COOLING FAN
NOTE: For some models of lift trucks, the battery does (DRIVE) SHAFT 3. BRUSH COVER
not need to be removed to access the electric motors.
Figure 1. Traction Motor
Other models will require the removal of the battery be-
fore gaining access to the electric motors. To remove
1
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620 YRM 294 Stoning the Commutator
Legend for Figure 6
1. RAISE DRIVE 3. BATTERY
WHEELS 4. BRUSH SEATER
2. JUMPER STONE
Figure 6. Stoning the Commutator
11
--- Page 7 ---
620 YRM 294 Tests for Damaged Field and Armature
TEST FOR SHORT CIRCUIT IN ONE must have experience to hear and understand the dif-
ARMATURE WINDING ference in sound. A winding with a short circuit will also
run hotter than a good winding and can have indications
A short circuit in a motor winding is difficult to test be- of heat damage.
cause of the normal low resistance (less than 1 ohm)
of a good armature. Special equipment is necessary Another indication of a short circuit will be a higher than
to check for a short circuit in a motor winding. A motor normal current draw by the motor. A higher than nor-
with a short circuit in an armature winding will have a mal current draw can also indicate other problems or
different sound when it begins to operate, but a service needed adjustments and does not always indicate a
person must have experience to hear and understand short circuit in a motor winding.
the difference in sound. A winding with a short circuit
will also run hotter than a good winding and can have
indications of heat damage. A winding that shows heat
damage when the other windings are normal can have
a short circuit.
Another indication of a short circuit will be a higher than
normal current draw by the motor. A higher than nor-
mal current draw can also indicate other problems or
needed adjustments and does not always indicate a
short circuit in a motor winding.
TEST FOR SHORT CIRCUIT TO
ARMATURE SHAFT
NOTE: Clean the dirt and brush dust from the commu-
tator area before making a test for a short circuit. 1. ARMATURE SHAFT 3. PROBES TO
2. COMMUTATOR OHMMETER
An ohmmeter (R Γ 10,000 scale) can be used to test for
Figure 16. Test for Armature Short Circuit
a short circuit between an armature winding and the ar-
mature shaft. Put one probe on the armature shaft and
the other probe on a commutator bar. See Figure 16. A
resistance of less than 1 megohm indicates a problem
between a winding and the armature shaft.
TEST FOR OPEN CIRCUIT IN FIELD COIL
The field windings in large electric motors normally have
less than 1 ohm of resistance. If an ohmmeter (R Γ
1 scale) is used to check the resistance between the
two terminals of the winding, a resistance greater than
1 ohm indicates a problem in that winding or corrosion
in the terminal connection. See Figure 17.
TEST FOR SHORT CIRCUIT IN FIELD COIL
A short circuit in a motor field winding is difficult to test
because of the normal low resistance (less than 1 ohm) 1. FIELD COIL 2. OHMMETER
TERMINAL
of a good field. Special equipment is necessary to
check for a short circuit in a motor winding. A motor Figure 17. Test for Open Field Circuit
with a short circuit in a field winding will have a different
sound when it begins to operate, but a service person
21
--- Page 8 ---
8000 YRM 982 Schematics
Figure 1. Schematic Diagram SEM MIB - II (Sheet 1 of 5)
1
--- Page 9 ---
8000 YRM 982 Schematics
Figure 3. Wiring Diagram Optional Equipment SEM MIB - II (Sheet 2 of 2)
11
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2200 YRM 978 General
General
The electrical control system consists of the following See the section Diagrams 8000 YRM 982 or 8000 YRM
major components (see Figure 1): 980 for additional information.
β’ Main Interface Board (MIB)
β’ Proportional Electro-Hydraulic Valve NOTE: Throughout this manual, the terms right, left,
β’ SEM Traction Motor Controller front, and rear relate to the viewpoint of an operator
β’ Dash Display Assembly standing in the truck facing the forks.
β’ Control Handle Assembly
β’ Contactor Panel Assembly
Figure 1. Logic Diagram
1
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2200 YRM 978 Fuses
Fuses
The fuses are located on the contactor panel assembly. When the lift truck has the provision for EE, the fuses
Lift off the cover for access to the contactor panel as- FU1, FU2, and FU3 are enclosed in a fuse box on the
sembly. contactor panel assembly. For access to the fuses, see
Figure 6. Remove the capscrews and lockwashers re-
taining the floor insulator, wall insulator, and the fuse
WARNING
box enclosure to the base plate to test or remove the
Disconnect the battery and separate the connector fuses.
before opening the compartment cover or inspect-
ing/repairing the electrical system. If a tool causes
a short circuit, the high-current flow from the bat-
tery can cause an injury or parts damage.
1. INSULATOR - TERMINAL 11. CAPSCREW
2. ENCLOSURE - FUSE BOX 12. INSULATOR - FLOOR
3. NUT 13. SPACER
4. LOCKWASHER 14. WASHER
5. SPACER 15. NUT
6. LOCK NUT 16. FUSE 400 AMPS
7. FUSE 100 AMPS 17. FUSE 325 AMPS
8. SCREW 18. INSULATOR - WALL
9. WASHER 19. LOCKWASHER
10. TERMINAL POST 20. CAPSCREW
Figure 6. Enclosed Fuse Box EE Application
11
--- Page 12 ---
2200 YRM 978 Main Interface Board (MIB)
3. Remove the battery compartment cover for access 7. Use a screwdriver in the slot of the lock on the con-
to the MIB. nector to release the male plug. Pull and hold the
lock away from the latch while pulling the J plugs
WARNING from the MIB. See Figure 16. Disconnect both the
J1 (white) and J2 (black) plugs from the MIB.
The capacitor in the traction motor controller can
hold an electrical charge after the battery is discon-
nected. To prevent electrical shock and injury, dis-
charge the capacitor before inspecting or repairing
any component. Wear safety glasses. Make cer-
tain the battery has been disconnected. Discharge
the capacitors in the controller by connecting a load
(such as a contactor coil or a horn) across the con-
trollerβs B+ and B terminals. DO NOT use a screw-
driver to discharge the traction motor controller.
4. Discharge the controller by connecting a load
across terminals B+ and B . See Figure 15.
Disconnect the two plugs from the main interface
board (MIB).
NOTE: PULL LOCK AWAY FROM THE CONNECTOR
TO DISCONNECT.
A. PULL
1. INSERT SCREWDRIVER INTO SLOT
Figure 16. MIB J Connector
8. Lift the MIB bracket high enough to allow removal
of the MIB.
NOTE: The MIB is not a repairable item and must be
replaced if there is a problem with the board itself.
MIB, INSTALL
WARNING
Disconnect the battery and separate the connector
1. NEGATIVE CONNECTION before opening the compartment cover or inspect-
2. POSITIVE CONNECTION ing/repairing the electrical system. If a tool causes
3. INSULATED JUMPER WIRES a short circuit, the high-current flow from the bat-
4. 200-OHM, 2-WATT RESISTOR
tery can cause an injury or parts damage.
Figure 15. Discharging the Capacitors
1. Move the lift truck to a safe, level area. Turn the key
5. Remove the screws retaining the MIB to the MIB switch OFF and remove the key. Put a DO NOT
bracket. OPERATE tag on the control handle. Put blocks
under the drive wheels to keep the lift truck from
6. Remove the capscrews and lockwashers retaining moving. See Periodic Maintenance 8000 YRM
the MIB bracket to the lift truck frame. 970. Refer to How To Put The Lift Truck On Blocks.
21
--- Page 13 ---
2200 YRM 978 Main Interface Board (MIB) Setup Procedures
Table 13. MIB Function Code Values for Table 14. MIB Function Code Values for NR045GB
NDR030CB (Continued) Mast Full Height less than 333 Inches (Continued)
Description Default Min./Max. Description Default Min./Max.
Value Value
Forward-Maximum* 219 0/+239 Slow Retract (SRT) 80 70/FRT
Mast Up Speed* 130 0/+143 Fast Retract (FRT) 130 SRT/160
NOTE: *Not more than 255. Tilt Down 95 0/105
Tilt Up 120 0/150
Table 14. MIB Function Code Values for NR045GB Sideshift Right 95 0/110
Mast Full Height less than 333 Inches
Sideshift Left 95 0/110
Description Default Min./Max. 36 Volt
Value 25
Lift-Minimum 10/80
Drive Dead Band 1 32 16/DDB2
Lift-Maximum 190 80/210
(DDB1)
Lower-Minimum 30 10/80
Drive Dead Band 2 64 DDB1/130
(DDB2) Lower-Maximum 170 80/190
Hydraulic Dead Band 1 32 16/HDB2 Lift Neutral 15 15/30
(HDB1) Lower Neutral 20 10/30
Hydraulic Dead Band 2 64 HDB1/130 36 Volt E
(HDB2)
Reverse-Maximum* 250 0/+255
Hydraulic Ramp 70 40/120
Forward-Maximum* 250 0/+255
Slow Reach (SRCH) 95 80/FRCH
Mast Up Speed* 130 0/+143
Fast Reach (FRCH) 160 SRCH/200
NOTE: *Not more than 255.
NOTE: *Not more than 255.
31
--- Page 14 ---
2200 YRM 978 Status Codes
Figure 18. Multifunction Control Handle Plug - Pin and Wire Identification
MIB Code Dash Display Message Priority Level Code Type Signal Source
06XX LIFT 27 STATUS MIB
Condition Logic
Multifunction control handle positioned for LIFTING. Displayed when MIB terminal J2-17 is 12 volts and MIB
terminal J2-14 increases from the neutral value.
Truck Response
Yellow LIFT/LOWER indicator illuminates.
Lift pump starts and forks lift.
MIB Code Dash Display Message Priority Level Code Type Signal Source
07XX LOWER 27 STATUS MIB
Condition Logic
Multifunction control handle positioned for LOWERING. Displayed when MIB terminal J2-17 is 12 volts and MIB
terminal J2-14 decreases from the neutral value.
Truck Response
Yellow LIFT/LOWER indicator illuminates.
Forks lower.
41
--- Page 15 ---
2200 YRM 978 Fault Codes
MIB Code Dash Display Message Priority Level Code Type Signal Source
XX57 HYDRAULIC HANDLE ERROR 12 FAULT MIB
Condition Refer to the Wiring Schematics
Hydraulic signal from handle is outside of neutral
band, but the neutral signal is high. Logic
Hydraulic signal from handle is outside of neutral
Truck Response band, but the neutral signal is high.
Lift - lower are disabled until brake is cycled.
Possible Causes and Test Procedures
β’ Neutral band is much too small; handle fault; faulty
wiring.
MIB Code Dash Display Message Priority Level Code Type Signal Source
XX58 HYDRAULIC HANDLE ERROR 12 FAULT MIB
Condition Refer to the Wiring Schematics
Hydraulic signal from handle is too low.
Logic
Truck Response Hydraulic signal from handle is less than 0.2 volt.
Lift - lower are disabled until brake is cycled.
Possible Causes and Test Procedures
β’ Handle fault; faulty wiring.
MIB Code Dash Display Message Priority Level Code Type Signal Source
XX59 HYDRAULIC HANDLE ERROR 12 FAULT MIB
Condition Refer to the Wiring Schematics
Hydraulic signal from handle is too high.
Logic
Truck Response Hydraulic signal from handle is greater than 4.8 volts.
Lift - lower are disabled until brake is cycled.
Possible Causes and Test Procedures
β’ Handle fault; faulty wiring.
51
--- Page 16 ---
2200 YRM 978 Programmer Handset
Figure 23. Programmer Handset Self Test
OPERATING MODES Table 18. Program Menu (Continued)
Program Menu Program Menu
Description
Display
Press the PROGRAM key to enter the PROGRAM
mode. See Table 18. The LED in the corner of the M1 Brake C/L Mode 1 braking current, in
PROGRAM key illuminates to indicate that the pro- amps
grammer has been placed in the PROGRAM mode.
M3 Neut Brk % Mode 3 neutral braking, as %
All of the adjustable functions and features are shown
of brake C/L
in the display window, four at a time, with the corre-
sponding settings. The setting of the selected item (the M2 Neut Brk % Mode 2 neutral braking, as %
item at the top of the display with the flashing arrow) of brake C/L
can be changed using the CHANGE VALUE keys. The M1 Neut Brk % Mode 1 neutral braking, as %
CHANGE VALUE keys have LEDs to indicate whether of brake C/L
the key can be used to increase or decrease the value
any further. When the LED is no longer lit, the limit for M3 Accel Rate Mode 3 acceleration rate, in
the key direction has been reached. seconds
Press the MORE INFO key to display more detailed in- M2 Accel Rate Mode 2 acceleration rate, in
formation for the setting selected, including a bar graph seconds
indicating the position of the current setting relative to M1 Accel Rate Mode 1 acceleration rate, in
the range for the setting, the unit of measure, and the seconds
specific minimum and maximum values for the setting.
Taper Rate Regen braking decrease rate,
If the range is limited by the values assigned for a dif-
when transitioning to plug, in
ferent function, the name of the limiting function is dis-
1/32 seconds
played in place of the minimum and maximum values.
M3 Max Speed Mode 3 maximum speed, as
Table 18. Program Menu % of top speed
Program Menu M2 Max Speed Mode 2 maximum speed, as
Description % of top speed
Display
M3 Brake C/L Mode 3 braking current, in M1 Max Speed Mode 1 maximum speed, as
amps % of top speed
M2 Brake C/L Mode 2 braking current, in
amps
61
--- Page 17 ---
2200 YRM 978 Troubleshooting
LED Code Dash Display Message Programmer Handset Display Message
DRIVE CTRL FAULT CHECK M FAULT
1, 3
FAULT CODE
Condition
Handset is plugged into the traction motor
controller. Key switch is in the ON position.
Diagnostic menu is selected.
Truck Response
Traction is disabled until fault condition is corrected.
Possible Causes and Test Procedures
β’ M output shorted or internal short in the traction
motor.
Verify voltage between battery and M to be Logic
10% less than battery volts, with the multifunction M bus bar should measure approximately 10%
control handle in neutral. less than battery volts. Pin 2-7 should measure
β’ Traction motor shorted. near zero volts, with multifunction control handle in
Check traction motor for shorted condition. neutral. Pin 2-7 should measure near battery voltage,
with corresponding direction selected.
LED Code Dash Display Message Programmer Handset Display Message
DRIVE CTRL LIMIT SPEED OVERVOLTAGE
4, 2
REDUCED OVERVOLTAGE
Condition
Handset is plugged into the traction motor
controller. Key switch is in the ON position.
Diagnostic menu is selected.
Truck Response
Traction is disabled until fault condition is corrected.
Possible Causes and Test Procedures
β’ Truck voltage greater than 45 volts.
Check to ensure proper battery is in the truck.
β’ Plugging the charger into the truck instead of the bat-
tery can also cause this fault.
Check to ensure the proper battery charging pro-
cedure is followed.
Logic
Traction controller is designed to operate with
24- and 36-volt batteries only.
71
--- Page 19 ---
100 YRM 975 Covers, Panels, and Plates
Legend for Figure 2
1. WASHER 13. CLIPNUT
2. LOCKWASHER 14. LOCKWASHER
3. CAPSCREW 15. CAPSCREW
4. CAPSCREW 16. CAPSCREW
5. MOUNTING CLIP 17. SPRING CLIP
6. CUSHION 18. SPRING CLIP MOUNTING BAR
7. CUSHION 19. BATTERY COMPARTMENT COVER
8. CUSHION 20. BATTERY SIDE PLATE
9. WASHER 21. BATTERY ROLLER ASSEMBLY
10. CAPSCREW 22. LINER
11. DOOR WELDMENT 23. CAPSCREW
12. HINGE PIN
1. ROLL PIN 4. BEARING
1. AXLE SHAFT 5. BEARING 2. AXLE 5. LOAD WHEEL
2. WASHER 6. LOAD WHEEL 3. SPACER ASSEMBLY
3. BRACKET 7. NUT
4. AXLE SLEEVE Figure 4. Single Load Wheel
Figure 3. Tandem Load Wheels
5
--- Page 20 ---
Hydraulic System Table of Contents
TABLE OF CONTENTS
General................................................................................................................................................................ 1
Description .......................................................................................................................................................... 1
Control Handle..................................................................................................................................................... 2
Description ...................................................................................................................................................... 2
Control Valve ....................................................................................................................................................... 2
Description ...................................................................................................................................................... 2