Periodic Maintenance

Maintenance
PERIODIC
MAINTENANCE
NDR030DB, NR035/040DB [B295];
NDR035EB, NR045EB [D861];
NDR030EB, NR035/040EB [E815]
PART NO. 550072991 8000 YRM 1617

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Yale® dealer.
Service Manuals provide general guidelines for maintenance and service and are intended for use by
trained and experienced technicians. Failure to properly maintain equipment or to follow instructions
contained in the Service Manual could result in damage to the products, personal injury, property damage
or death.
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the
load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the
weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks.
Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK
ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use YALE APPROVED parts when making repairs. Replacement parts must meet or exceed the
specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to
remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs
repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable.
Be sure to follow the necessary safety precautions when handling these fuels and when working on these
fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area.
Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this man-
ual:
WARNING
Indicates a hazardous situation which, if not avoided, could result in death
or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
Table of Contents
TABLE OF CONTENTS
General ..................................................................................................................................................................... 1
Removing Covers ................................................................................................................................................. 2
Front Frame Panel (Left and Right) .................................................................................................................. 2
Operator Compartment Cover ...........................................................................................................................2
Drive Unit Compartment Door ...........................................................................................................................3
Caster Wheel Cover ..........................................................................................................................................3
Discharging the Capacitors ...................................................................................................................................3
How to Move Disabled Truck ................................................................................................................................ 4
How to Tow Lift Truck ........................................................................................................................................4
How to Put Lift Truck on Blocks ............................................................................................................................ 5
How to Raise Load Wheels ...............................................................................................................................5
How to Raise the Drive Tire End .......................................................................................................................5
How to Raise the Entire Lift Truck .....................................................................................................................6
Manual Lowering Valve .........................................................................................................................................7
Transporting ..............................................................................................................................................................8
Loading ................................................................................................................................................................. 8
Unloading ..............................................................................................................................................................9
Preparation for Use ...................................................................................................................................................9
Preparation After Shipment ...................................................................................................................................9
Preparation After Storage ..................................................................................................................................... 9
Safety Procedures When Working Near Mast .......................................................................................................... 9
Maintenance Schedule ............................................................................................................................................11
Maintenance Procedures Every 8 Hours or Daily ...................................................................................................17
Checks With Key Switch Turned OFF .................................................................................................................18
Battery .............................................................................................................................................................18
Tires and Wheels ............................................................................................................................................ 19
Frame and Load Wheels .................................................................................................................................19
Safety Labels .................................................................................................................................................. 19
Overhead Guard ............................................................................................................................................. 19
Forks Check ....................................................................................................................................................20
Lift Chain Check ..............................................................................................................................................21
Mast Check ..................................................................................................................................................... 22
Reach, Tilt, and Sideshift ................................................................................................................................ 22
Checks With Key Switch Turned ON .................................................................................................................. 22
Operation ........................................................................................................................................................ 22
Hydraulic System ............................................................................................................................................ 23
Dash Display ...................................................................................................................................................23
Lift System Operation ......................................................................................................................................24
Multifunction Control Handle ...........................................................................................................................25
Brake ...............................................................................................................................................................26
Steering System ..............................................................................................................................................26
Maintenance Procedures Every500 Hours or 3 Months ......................................................................................... 26
Master Drive Unit ................................................................................................................................................ 26
Hydraulic System ................................................................................................................................................ 26
Hydraulic Filter Element Change ........................................................................................................................ 28
Caster Adjustment .............................................................................................................................................. 28
Elastomer Spring Adjustment ..........................................................................................................................29
Spring Pack Replacement ...............................................................................................................................30
Remove Spring Assembly ...........................................................................................................................30
Replace Spring Pack ...................................................................................................................................30
Install Spring Assembly ...............................................................................................................................31
Drive Tire Check ................................................................................................................................................. 31
©2018 Yale Materials Handling Corp. i

Table of Contents
TABLE OF CONTENTS (Continued)

Lift System Operation ......................................................................................................................................... 32
Forks Check ....................................................................................................................................................32
Mast ................................................................................................................................................................ 32
Lift Chains ....................................................................................................................................................... 33
Other Lubrication ................................................................................................................................................ 34
Maintenance Procedures Every 2000 Hours or Yearly ........................................................................................... 34
Brakes .................................................................................................................................................................34
Check ..............................................................................................................................................................34
Electric System ................................................................................................................................................... 34
Main Contactor ................................................................................................................................................34
Inspect .........................................................................................................................................................34
Forks, Check .......................................................................................................................................................35
Hydraulic System ................................................................................................................................................ 35
Drain ................................................................................................................................................................35
Cylinder Identification ..................................................................................................................................37
Fill ....................................................................................................................................................................38
Main Lift Cylinders .......................................................................................................................................39
Free-Lift Cylinders .......................................................................................................................................39
Hydraulic Filter Change ...................................................................................................................................40
Check Hydraulic Strainer ................................................................................................................................ 41
Lift and Tilt System Leaks Check ............................................................................................................................41
Lift System .......................................................................................................................................................... 41
Tilt System .......................................................................................................................................................... 42
Battery Maintenance ...............................................................................................................................................42
How to Charge Battery ........................................................................................................................................42
How to Change Battery .......................................................................................................................................44
Tires and Wheels .................................................................................................................................................... 46
Drive Tire .............................................................................................................................................................46
How to Change Drive Tire ...................................................................................................................................47
Tandem Load Wheels ......................................................................................................................................... 48
Caster Wheels .................................................................................................................................................... 48
Remove ...........................................................................................................................................................48
Install ...............................................................................................................................................................49
Preparation for Storage .......................................................................................................................................... 50
Short-Term Storage (1 to 6 months) ................................................................................................................... 50
Long-Term Storage (6 months or longer) ............................................................................................................50
This section is for the following models:
(NDR030DB, NR035/040DB) [B295];

(NDR035EB, NR045EB) [D861];
(NDR030EB, NR035/040EB) [E815]
ii
8000 YRM 1617 General
General
The Maintenance Schedule is divided into three time
WARNING intervals which call for particular maintenance
procedures to be performed. The intervals are 1 Day
DO NOT make repairs or adjustments unless you
or 8 hours, 3 Months or 500 Hours, and 1 Year or 2000
have been properly trained and specifically
Hours for normal operations (whichever comes first).
authorized to do so. Repairs and adjustments that
Normal operation is considered one 8-hour shift per
are not correct can create dangerous operating
day, in a relatively clean environment, on an improved
conditions.
surface. Operating a lift truck for more than eight hours
DO NOT operate a lift truck that needs repairs. per day is considered Heavy operation and requires
Report the need for repairs to your supervisor the 3-month checks to be performed at 350 hours. Lift
immediately. If repair is necessary, disconnect the trucks operating in freezer environments or dirty
battery and attach a DO NOT OPERATE tag to the conditions are considered Severe operation and
control handle. require the 3-month checks to be performed at 200
hours.
Your lift truck dealer has the facilities and trained
CAUTION personnel to perform required maintenances. A
Electrical components on this truck are polarity complete program of inspection, lubrication, and
sensitive and may be damaged if wired incorrectly. maintenance will help your lift truck perform efficiently
Make sure each electrical wire connection is and operate over a longer period of time.
tagged and properly identified before removal or
installation. If the proper location for connection is Some users have service personnel and facilities to
unclear, consult the wiring diagram for the truck. perform the tasks listed in the Maintenance Schedule.
Make sure testing meters have adequate voltage Service Manuals are available from your lift truck
and current capacities to handle the output of the dealer to help users who do their own maintenance.
electrical components they are used to check. DO NOT make repairs or adjustments unless you have
Never wire aftermarket components to this truck been properly trained and specifically authorized to do
without factory approval. so.
Certain welding repairs require factory approval. Put the lift truck on a level surface. Lower the carriage
Structural members such as base arms, axle and forks, apply the parking brake, and turn the key
weldments, and mast components require written switch to the OFF position. Open the access panels
Yale® engineering approval before repairing or and inspect for leaks and conditions that are not
replacing. Contact your local dealer for assistance. normal. Clean any oil spills. Make sure that lint, dust,
paper, and other materials are removed from the
This section contains a Maintenance Schedule and the compartments.
instructions for maintenance and inspection.
1
General 8000 YRM 1617
REMOVING COVERS against the frame and tighten the screws to secure in
place. See Figure 1.
Front Frame Panel (Left and Right)
Remove the screws from the upper and lower ends of Operator Compartment Cover
the front frame panel. Pull the lower end of the panel Remove the front frame panels from the lift truck.
away from the frame of the lift truck and gently work up Refer to Front Frame Panel (Left and Right). Remove
the side of the panel to pull it from the retainer clips the two screws securing the operator cover to the
securing the panel to the frame. Pull the top end tabs frame brackets. One is located on the lower right side
out of the operator compartment cover. Repeat for of the operator compartment above the operator
opposite side as necessary. See Figure 1. presence switch. The other is located beside the
overhead guard post mount, at the bottom of the cup
holder. Pull the operator compartment cover up from
the front right corner. Continue pulling the cover up
along the edge of the frame in both directions until the
cover is free from the retaining clips. See Figure 2.
To install, position the cover over the electrical
compartment. See Figure 2. Align the lip of the cover
to the retaining clips. Press the lip of the cover into the
retaining clips starting at the overhead guard post and
continue around until completely seated. Align the
holes in cover with the mounting brackets and install
retaining screws as removed. Install the front frame
panels to complete assembly. Refer to
Front Frame Panel (Left and Right) in this section.
1. OPERATOR COMPARTMENT COVER

2. FRAME
3. LOWER BRACKET
4. LOWER SCREW
5. FRONT FRAME PANEL (LEFT)
6. TABS
7. UPPER BRACKET
8. UPPER SCREW
Figure 1. Front Frame Panel (Left Side)
NOTE: On right side front frame panels, ensure the

diagnostic connector cap is positioned to allow the
cover to seat properly.
To install the panel, position the upper end of the panel
partially into the retaining clip on the frame. Insert the
tabs on the upper end of the panel into the slots in the 1. OPERATOR COMPARTMENT COVER
2. OVERHEAD GUARD POST MOUNT
operator compartment cover. Work the sides of the 3. FRAME
panel into the retaining clips until all areas of the panel 4. FRONT FRAME PANEL (LEFT)
are aligned with the frame. Align the holes in the panel
with the mounting brackets on the frame and loosely Figure 2. Operator Compartment Cover
install the screws into the upper end and lower end of
the panel. Make certain the panel is seated correctly
2
Drive Unit Compartment Door 3. Remove the operator compartment cover.

Completely loosen the two socket head capscrews 4. Discharge the capacitor in the controllers by
securing the drive unit compartment door closed. The connecting a 200-ohm, 2-watt resistor across the
screws are spring loaded and retained to the door by controller B+ and B- terminals of the motor
clips. Pull the door open on its hinges. To close, push controller for 10 seconds. Remove the resistor
the door closed and start both socket head capscrews after discharging the capacitors. See Figure 3.
loosely into the mounting holes. When both screws are
started, verify that the door seats properly against the
frame and tighten the screws.
Caster Wheel Cover

Remove the socket head capscrews on top of the
caster wheel cover and lift cover from the clips
securing it to the frame.
To replace, fit the bottom of the cover into the clips
inside the opening and slide the cover into place.
Install two socket head capscrews to secure the top of
the cover in place.
DISCHARGING THE CAPACITORS
WARNING
Capacitors inside the controllers can hold an
electrical charge after the battery is disconnected.
Discharge the capacitors before servicing the
electrical system to prevent injury or electronic 1. POSITIVE CONNECTION (B+)
damage. 2. NEGATIVE CONNECTION (B-)
3. INSULATED JUMPER WIRES
1. Move the lift truck to a safe, level area and 4. 200-OHM, 2-WATT RESISTOR
completely lower the mast. Turn the key switch to
Figure 3. Discharging the Capacitors
the OFF position and attach a DO NOT
OPERATE tag to the control handle. Block the
drive wheel to prevent unexpected movement.
2. Disconnect the battery power cable connector

from the truck connector located on the right side
of the frame. Pull the battery cable connector
handle to separate the battery connector from the
truck connector.
3
HOW TO MOVE DISABLED TRUCK 2. Raise the carriage and forks approximately
30 cm (12 in.) from the surface. Use safety chains
How to Tow Lift Truck to secure in place if the mast is not functional.
3. Attach a towing strap of adequate capacity to the

WARNING
LOWER truck frame beneath the operator's
Use extra care when moving a lift truck during the compartment.
following conditions:
• Brakes do not operate correctly. 4. If a counterbalanced lift truck is used to tow the
• Steering does not operate correctly. disabled lift truck, that lift truck must have an
equal or larger capacity than the disabled lift
• Tires are damaged. truck. If an increased load will increase the load
• Traction conditions are bad. on the drive tire(s), install an approximate half-
• The lift truck must be moved on a steep capacity load on the forks of the lift truck that is
grade. being used to tow the disabled lift truck. This half-
capacity load will increase the traction of the lift
Poor traction can cause the disabled lift truck or
truck. Keep the load as low as possible.
towing vehicle to slide. Steep grades will require
additional brake force to stop the lift truck.
Never carry a disabled lift truck unless the lift WARNING
truck MUST be moved and cannot be towed. The If towing a lift truck equipped with a steered caster,
mast MUST be removed before the lift truck can be the caster may resist tracking with the drive wheel.
lifted. The lift truck used to carry the disabled lift
truck MUST have a rated capacity equal to or The towed lift truck must have an operator.
greater than the weight of the disabled lift truck.
5. Tow the lift truck slowly.
The capacity must be for a load center equal to
half the width of the disabled lift truck. See the
nameplate of the disabled lift truck for the
approximate total weight. The forks must extend
the full width of the disabled lift truck. Center the
weight of the disabled lift truck on the forks and be
careful not to damage the under side of the lift
truck.
If towing a lift truck equipped with a steered caster,
the caster may resist tracking with the drive wheel.
If there is no electrical power to the lift truck, the
electric parking brake will not automatically
release and the steering will not operate.
NOTE: The parking brake can be manually released

by installing two service capscrews into the brake
assembly. Ensure the two capscrews are removed
prior to returning to the lift truck to service.
1. Manually release the parking brake if problems
prevent it from releasing normally.
a. Insert two 1/4-20 × 1 (UNC) capscrews into the 1. CAPSCREWS (1/4-20 × 1)

two holes on the outer edge of the top of the 2. MANUAL RELEASE HOLE
parking brake assembly. See Figure 4. 3. BRAKE ASSEMBLY
4. ASSEMBLY HOLES
b. Tighten the capscrews alternately until the
brake is released. Figure 4. Manual Release
4
6. Remove the capscrews from the brake, lower the 1. Put blocks on both sides (front and back) of the
mast, and disconnect the towing strap when drive/steer tire and the caster wheels to prevent
complete. movement of the lift truck. See Figure 5.
HOW TO PUT LIFT TRUCK ON BLOCKS 2. Use an overhead crane and web sling under the
base arms at the mast to raise the load wheels.
Another lift truck can also be used to raise the
WARNING base arms. Make sure that the crane and sling or
The lift truck must be put on blocks or an other lifting device has a capacity of at least 2/3 of
approved stand for some types of maintenance the total weight of the lift truck as shown on the
and repair. The removal of the following nameplate.
assemblies will cause large changes in the center
of gravity: mast and load axle, battery, and the 3. Raise the base arms only enough to suspend the
counterweight. When the lift truck is put on blocks, wheels. Install blocks under the base arms at the
put additional blocks under the rear of the frame rear of the wheels near the truck frame to support
before removing the mast so the lift truck cannot the lift truck.
fall backward or to the side.
How to Raise the Drive Tire End
DO NOT raise any point of the truck more than
50 mm (2 in.) without raising the opposite side to Refer to the precautions at the beginning of the
level the truck. If raising the frame above Figure 5, How to Put Lift Truck on Blocks instructions
150 mm (6 in.) remove the mast first and raise both in this section before attempting to raise the lift truck.
ends of the frame in 50 mm (2 in.) increments.
1. Put blocks on each side (front and back) of the
DO NOT raise the lift truck by attaching an load wheels to prevent movement of the lift truck.
overhead crane to the overhead guard or areas of See Figure 5.
the mast that will be damaged. Some of these
components and other lift points are not designed 2. Use a low-clearance, hydraulic jack under the
to support the weight of the lift truck. The truck rear of the frame to raise the drive/steer tire and
can be damaged or it can fall on someone causing caster wheels. Another lift truck can also be used
serious injury. Attach a chain or sling to a support to raise the lift truck. Make sure that the jack or
structure of the lift truck frame. other lifting device has a capacity of at least 2/3 of
the total weight of the lift truck as shown on the
Put the lift truck on blocks only if the surface is solid, nameplate.
even, and level. Make sure that any blocks used to
support the lift truck are solid, one-piece units. Put 3. Raise the lift truck only enough to suspend the
blocks in front and back of the tires to prevent drive/steer tire and the caster wheels. Install
movement of the lift truck. blocks under the rear of the frame to support the
lift truck.
How to Raise Load Wheels
Refer to the precautions at the beginning of the
Figure 5, How to Put Lift Truck on Blocks instructions
in this section before attempting to raise the lift truck.
5
How to Raise the Entire Lift Truck 3. Remove the battery from the lift truck.
Refer to the precautions at the beginning of the
Figure 5, How to Put Lift Truck on Blocks instructions
in this section before attempting to raise the lift truck. WARNING
The truck must be kept level while raising.
WARNING 4. Raise the lift truck and position solid, one-piece

The mast MUST BE REMOVED to raise the frame hardwood blocks or an approved lift truck frame
above 150 mm (6 in.). stand under the frame. The truck must be kept
level while raising. Frequently reposition jack
1. Remove the mast from the lift truck. Refer to stands or blocks under the frame while raising as
Mast 4000YRM1195. a safety precaution in case of equipment failure.
DO NOT raise any point of the frame
2. Turn the key switch to the OFF position and 50 mm (2 in.) more than any other point of the
disconnect the battery from the lift truck at the frame.
battery connector.
WARNING
The battery is heavy. Use appropriate lifting
equipment to avoid personal injury.
1. DRIVE AND CASTER WHEELS 2. LOAD WHEELS
Figure 5. How to Put Lift Truck on Blocks
6
MANUAL LOWERING VALVE

NDR030/035EB and NR030/040/045EB
WARNING
Allow no on under or near the lift mechanism or
load during the manual lowering procedure.
Always verify that there are no obstructions
beneath the lift mechanism or load before
attempting to lower the mast manually.
The manual lowering valve is located on the main lift

pump manifold beside the hydraulic tank. The manual
lowering valve can be opened by turning the valve
knob counterclockwise to relieve pressure from the
hydraulic system. This can be used to manually lower
the mast in case of malfunction or to relieve pressure
from the system before servicing the hydraulics. If the
mast leaks down during operation, lower the mast and
check that the knob is completely closed (turn
clockwise). Always close the manual lowering valve
after use. See Figure 6.
NDR030DB and NR035/040DB 1. LOWERING CONTROL VALVE

2. UPPER MOUNTING HOLE
3. M2 TEST PORT
4. MANUAL LOWERING VALVE KNOB
WARNING 5. M1 TEST PORT
Allow no on under or near the lift mechanism or 6. RETURN FITTING
load during the manual lowering procedure. 7. RELIEF VALVE
8. SUPPLY FITTING
Always verify that there are no obstructions 9. LOWER MOUNTING HOLE
beneath the lift mechanism or load before 10. OVERRUN CHECK VALVE
attempting to lower the mast manually. 11. PRESSURE FLANGE
Manual lowering is accomplished by pushing in the Figure 6. Pump (Valve Manifold)

manual lowering valve knob and turning it
counterclockwise 180° until the knob pops back out.
See Figure 7. This will open the valve and the mast
will begin lowering at a controlled rate. Push the load
holding check valve knob in and turn it clockwise 180°
until it pops back out to close. See Figure 7.
7
Transporting 8000 YRM 1617
Legend for Figure 7.
A. MANUAL LOWERING VALVE KNOB

B. MAIN CONTROL VALVE BODY
Figure 7. Main Control Valve
Transporting
If a loading ramp is used, make sure that the ramp is
WARNING the proper design and capacity.
Maintain a safe distance from the edge of docks, Use approved lifting eyes to lift the truck. If the lift truck
ramps, platforms, and other similar working is not equipped with approved lifting eyes, DO NOT lift
surfaces. Watch the "tailswing." Remember, when the truck by attaching a lifting device to any other part
traveling in the forward direction, and the steering of the lift truck for the purposes of loading or
wheel is turned to move the lift truck away from unloading.
the edge of the dock, the rear will swing toward the
edge. This can cause the lift truck to fall off the LOADING
dock. If components attached to the lift truck must be
If the lift truck falls off the dock, DO NOT jump off! removed for transport, refer to the section(s) for those
Hold firmly to the steering wheel, brace your feet, components for proper handling procedures.
and lean forward and away from the point of The operator must never leave a lift truck in a
impact. condition so it can cause damage or injury. When
parking the lift truck, do the following operations:
Before the lift truck is transported, check the selected
route to make sure there is adequate clearance for the
1. After the lift truck has been loaded, apply the
lift truck as loaded on the transport vehicle (bridges,
parking brake.
overpasses, power lines, and natural barriers). In
some cases, removal of the mast can be required. 2. If the mast is mounted on the lift truck, fully lower
If a trailer is the method of transportation, use blocks in the forks or carriage. If the lift truck is furnished
front and back of the trailer tires to prevent movement with a tilt mechanism, tilt the forks forward until
of the trailer when the lift truck is loaded and unloaded. the tips of the forks touch the ground.
8
8000 YRM 1617 Preparation for Use
3. Turn the key switch to the OFF position to stop

6. If the lift truck is transported in severe weather or
the engine.
any other condition that can damage the lift truck,
cover the lift truck. Make sure the tarp or
4. Check that all switches and accessories are
protective material is designed for the application
turned off.
and is securely attached.
5. Put blocks in front and back of the lift truck tires to
prevent any movement of the lift truck. Make sure UNLOADING
the blocks are attached to the transport surface. If components attached to the lift truck must be
removed for transport, refer to the section(s) for those
components for proper handling procedures.
WARNING
The straps or chains used to attach the lift truck to 1. If used, remove any covering.
the transporter must be directly attached to the lift
truck frame or to a component (drive axle, tow pin) 2. Make sure the park brake is applied.
that is solidly attached to the frame. DO NOT
attach the straps or chains to the mast or any 3. Disconnect the straps or chains.
attachment.
4. Remove the wheel blocks.
5. Check that all switches and accessories are

CAUTION turned off.
Make sure that any straps or chains used to attach
the lift truck to the transporter do not contact any 6. Unload the lift truck.
tubes, hoses, hydraulic cylinders, or other parts of
the lift truck that are easily damaged.
Preparation for Use

2. Inspect the lift truck for damage and missing
CAUTION components.
Transporting trucks in the horizontal position may
3. Follow the steps in the section
cause some looseness in the mast chains, hoses,
Maintenance Procedures Every 8 Hours or Daily.
and other components. Always check for loose or
shifted components before raising the mast. Raise
PREPARATION AFTER STORAGE
the mast very slowly after standing the truck up, to
ensure all hoses and chains are properly seated in 1. Remove all tape, covers, and preservation
their respective sheaves and anchor points. Raise materials.
the mast up and down a few times to ensure the
hoses and chains are working and adjusted 2. Check the lift truck for damaged or missing
properly. If the truck is equipped with components. Repair damage and/or replace
displacement main or free-lift cylinders, the missing components.
cylinders should be bled. See Lift Cylinders
4000YRM0481. NOTE: If the lift truck has been stored longer than 1
year, all lubricants and fluids must be drained and
After being transported or stored, the lift truck must be replaced. Refer to Maintenance Schedule.
prepared for proper operation. All problems must be 3. Clean battery cables. Check the battery voltage. If
corrected before use of the lift truck. See the proper the voltage is less than nominal, charge the
section for component repair procedures. battery. Connect the cables to battery and tighten.
PREPARATION AFTER SHIPMENT 4. Follow the steps in the section

1. Complete the unloading procedures. Maintenance Procedures Every 8 Hours or Daily.
9
Safety Procedures When Working Near Mast 8000 YRM 1617
Safety Procedures When Working Near Mast

The following procedures must be used when 2. If parts of the mast must be in raised position,
inspecting or working near the mast. Additional install a safety chain to restrain the moving parts
precautions and procedures can be required when of the mast. Connect moving parts to a part that
repairing or removing the mast. does not move. Follow these procedures:
a. Raise the mast to align the bottom

WARNING crossmember of the weldment that moves in
Mast parts are heavy and can move. Distances the outer weldment with a crossmember on the
between parts are small. Serious injury or death outer weldment (1). See Figure 8.
can result if part of the body is hit by parts of the
mast or the carriage. b. Use a 3/8-in. minimum safety chain with a
Never put any part of the body into or under hook (4) to fasten the crossmembers together
•
the mast or carriage unless all parts are so that the movable member cannot lower. Put
completely lowered or a safety chain is the hook on the back side of the mast. Make
installed. Also make sure that the power is sure the hook is completely engaged with a
off and the key is removed. Put a DO NOT link in the chain. Make sure the safety chain
OPERATE tag in the operator's does not touch lift chains or chain sheaves,
compartment. Disconnect the battery on tubes, hoses, fittings, or other parts on the
electric lift trucks and put a tag or lock on mast.
the battery connector.
• Be careful of the forks. When the mast is c. Lower the mast until there is tension in the
raised, the forks can be at a height to cause safety chain, and the free-lift cylinder (5) is
an injury. completely retracted. Install a DO NOT
• DO NOT climb on the mast or lift truck at any REMOVE tag on the safety chain(s).
time. Use a ladder or personnel lift to work
on the mast. d. Install another safety chain (3/8 in. minimum)
• DO NOT use blocks to support the mast around the safety chain already installed as a
weldments nor to restrain their movement. secondary safety precaution. Hook the chain
Mast repairs require disassembly and as tight as possible by hand.
•
removal of parts and can require removal of
the mast or carriage. Follow the repair 3. After lowering or restraining the mast, shut off the
procedures in the correct Service Manual power and remove the key. Put a DO NOT
section for the mast. OPERATE tag in the operator's compartment.
Disconnect the battery and put a tag or lock on
WHEN WORKING NEAR THE MAST, ALWAYS: the battery connector.
1. Lower the mast and carriage completely. Press

the lower button on the control handle. If the
lowering controls do not operate correctly, slowly
open the lowering control valve to relieve
pressure from the hydraulic system. and make
sure there is no movement in the mast. Make
sure that all parts of the mast that move are fully
lowered.
OR
10
8000 YRM 1617 Maintenance Schedule
1. OUTER MAST
2. INNER MAST
3. INTERMEDIATE MAST
4. HOOK
5. FREE-LIFT CYLINDER
6. CROSSMEMBER
7. CROSSMEMBER
Figure 8. Safety Chains
Maintenance Schedule
NOTE: Certain components on the truck require an 2000 Hours for normal operations (whichever comes
initial inspection earlier than the prescribed first). Normal operation is considered one 8-hour shift
maintenance schedule to preserve the original per day, in a relatively clean environment, on an
manufacturer's warranties. Perform the 3 month 500 improved surface. Operating a lift truck for more than
hour inspection at 150 to 250 hours after the initial eight hours per day is considered Heavy operation
installation of the truck and then follow the scheduled and requires the 3-month checks to be performed at
inspections as listed in the maintenance schedule (see 350 hours. Lift trucks operating in freezer
the notes after Table 1). environments or dirty conditions are considered
Severe operation and require the 3-month checks to
The Maintenance Schedule is divided into three time
be performed at 200 hours. For an approximate
intervals which call for particular maintenance
location of the items listed in Table 1, see Figure 9.
procedures to be performed. The intervals are 1 Day
or 8 Hours, 3 Months or 500 Hours, and 1 Year or
11
Maintenance Schedule 8000 YRM 1617
Figure 9. Maintenance Points
Table 1. Maintenance Schedule
Item Item 1 day/ 3 mo/ 1 yr/ Procedure or Specification

No. 8 hr 500 hr 2000 Quantity
hr
1 Battery X, C1 Check for Full Charge Charge or Change Out
Fluid Level X Check Distilled Water
Restraint X Check Condition Repair as Necessary

Panels
Power X Check Operation Repair as Necessary

Disconnect
X=Check C=Change L=Lubricate
12
Table 1. Maintenance Schedule (Continued)

hr
2 Brake X Check Operation Repair as Necessary
X Hold on Grade Test Capacity Load on 10%

Slope
3 Control Handle X Check Operation Repair as Necessary
4 Electrical X Check Operation Repair as Necessary

Circuits
Contactors X Check Condition Repair as Necessary
5 Forks X X X Check for Damage Replace as Necessary
Guides and X L As Required Multipurpose Grease2

Locks
Sideshift X Check Wear Replace as Necessary

Wear
Bearings
6 Dash Display, X Check Operation Repair as Necessary

Horn, Lights,
Fuses
7 Hydraulic X Visually Inspect for Repair as Necessary

System Leaks
X Check for Proper Repair as Necessary

Operation
X Check Level See Table 2
C Change Oil (Standard ISO VG 46 Antiwear

Hydraulic
Operation)
Oil
C Change Oil (Freezer Exxon Univis® HVI 26

Applications)
13

hr
Breather X Inspect Replace as Necessary

Cap
Hydraulic C4 C Replace See Parts Manual

Oil Filter
Hydraulic X Inspect Replace as Necessary

Oil Strainer
X Inspect for Visible Adjust, Repair, or Replace

Hydraulic Damage and Defects as Necessary
Hoses,
Fittings,
and X Inspect for Kinked, Replace as Necessary
Clamps Flattened, Stiff, or
Charred Hoses
8 Lift Chains X Inspect for Visible Check Operation

Damage
X Check Stretch Replace as Necessary
L Lubricate as Required SAE 20 or 30 Engine Oil
9 Mast X Inspect for Visible Check Operation

Damage
Bleed Cylinders X Remove all air from See Cylinder Identification.

(Displacement cylinders using
Type Only) bleeder screws
Header Hoses, X Inspect for Visible Adjust, Repair, or Replace

Fittings, and Damage and Defects as Necessary
Clamps
X Inspect for Kinked, Replace as Necessary
Flattened, Stiff, or
Charred Hoses
Sliding Surfaces L2 As Required Multipurpose Grease2
14

hr
10 Reach Carriage X Inspect for Visible Check Operation

Assembly Damage
Single L 4 Lube Fittings Multipurpose Grease2

Reach
Scissor
Arms
Double L 8 Lube Fittings Multipurpose Grease2

Reach
Scissor
Arms
Reach L 4 Lube Fittings Multipurpose Grease2

Cylinder
Pivot Pins
Tilting L 2 Lube Fittings Multipurpose Grease2

Frame
Side Shift L 4 Lube Fittings Multipurpose Grease2

Carriage
11 Frame X Visually Inspect Repair as Necessary
Overhead X Visually Inspect Replace as Necessary

Guard
Door Hinges L Lightly Oil SAE 20 or 30 Engine Oil
12 Safety Labels X Replace if Necessary See Parts Manual

and Operating
Manual
13 Steering X Check Operation

Operation
15

hr
14 Caster and Load X Check Condition

Wheels
Caster X Check Condition

Wheel
Assembly
L 1 Lube Fitting Multipurpose Grease2
X Check Adjustment Adjust With Shims

Gap
Load L Check Condition/Lube Antiseize Lubricant

Wheel
Bolts
L Optional Grease Multipurpose Grease2
Fittings
Load L Apply to Saddle Pin Multipurpose Grease2

Wheel Points
Saddle Pin
15 Master Drive X Check Operation

Unit
MDU L Apply to Gear Multipurpose Grease2

Steering
Gear
MDU Gearcase
B295 and X Level With Bottom of Gear Oil52.2 liter (2.3 qt)
E815 Check Hole. Replace
(GK - 20) sealP/N 580017695
and tighten plug to 30
N•m (22 lbf ft)
D861 (GK X Level With Bottom of Gear Oil53.3 liter (3.5 qt)
- 25) Check Hole. Replace
seal P/N 580017695
and tighten plug to 30
N•m (22 lbf ft)
16

hr
16 Drive Wheel and X Check Condition

Tire
Tire X Inspect for Damage Smooth Edges/Remove

Embedded Objects
Axle Seal X Inspect for Leaks Remove Wrapped Debris
Wheel Lug X3 Tighten as Required 135 N•m (100 lbf ft)

Torque
1
Equalization charge approximately each month, but not more than each week.
2
Use Amsoil® GHD synthetic multipurpose grease (lithium complex) for standard, freezer, and cold storage
configurations. Use Mobilgrease® 28 synthetic extra-protection grease (clay) for arctic configurations.
3
Apply antiseize lubricant at installation and check every 2 to 5 hours until nuts stay tight for an entire 8-hour
shift. Check tightness every 3 months or 500 hours thereafter.
4
Replace the filter element after the first 150 to 250 hours of service and every 2000 hours or yearly thereafter.
5
Use Yale® P/N 310153236 conventional gear oil for normal operations. Use Yale® P/N 310153228 synthetic
gear oil for freezer applications.
17
Maintenance Procedures Every 8 Hours or Daily 8000 YRM 1617
Maintenance Procedures Every 8 Hours or Daily

The battery must fit the battery compartment so
WARNING the battery restraint panels will operate correctly.
Use spacers to prevent the battery from moving
DO NOT operate a lift truck that needs repairs. If a
more than 13.0 mm (0.5 in.) in any direction.
repair is necessary, put a DO NOT OPERATE tag in
the operator's area. Remove the key from the key
switch.
CAUTION
Inspect the lift truck every 8 hours or daily before use. Disposal of batteries must meet local
Put the lift truck on a level surface. Lower the carriage environmental regulations.
and forks, and turn the key switch to the OFF position.
If repair is required, put a tag in the operator's area Make sure the battery weight is within the maximum
that indicates the lift truck cannot be operated. DO and minimum weight shown on the nameplate.
NOT operate a lift truck until the problems are Keep the battery case, top cover, and the area for the
corrected. battery clean and painted. Leakage and corrosion from
the battery can cause a malfunction in the electric
CHECKS WITH KEY SWITCH TURNED controls of the lift truck. Use a water and sodium
OFF bicarbonate solution (soda) to clean the battery and
the battery area. Keep the top of the battery clean, dry,
Make the following checks:
and free of corrosion.
• Electrolyte and specific gravity of the battery
Make sure the battery is charged and has the correct
• Make sure the battery is clean and the correct voltage and ampere hour rating for the lift truck. See
size and weight for the lift truck the nameplate.
• Check that the battery restraint plates are in
Inspect the battery case, connector, and cables for
place
damage, cracks, or breaks. Contact your local battery
• Leaks in the hydraulic system dealer to discuss repair options for the battery case.
• Condition of the wheels and tires Check the level of the electrolyte daily on a minimum
• Condition of the forks, carriage, mast, and of one cell. The correct level is halfway between the
overhead guard top of the plates and the bottom of the fill hole. Add
only distilled water.
Battery Make certain the battery restraint panels are properly
installed.
WARNING
DO NOT put tools on the battery. WARNING
The acid in the electrolyte can cause injury. If the Make sure the key switch is in the OFF position
electrolyte is spilled, use water to flush the area. and the brake is set before connecting the battery.
Make the acid neutral with a solution of sodium If the lift truck was operated with a discharged
bicarbonate (soda). Acid in the eyes must be battery, check the contactor for welded tips before
flushed with water continuously for 15 minutes a charged battery is connected.
then seek medical attention.
Batteries generate explosive fumes. Keep the The battery should have an equalization charge each
vents in the caps clean. Keep sparks or open month, but not more than each week.
flames away from the battery area. DO NOT make a
spark from the battery connections. Disconnect
the battery when doing maintenance.
18
8000 YRM 1617 Maintenance Procedures Every 8 Hours or Daily
Tires and Wheels Overhead Guard
WARNING WARNING
When the wheels have been installed, check all DO NOT operate the lift truck without the overhead
wheel nuts after 2 to 5 hours of operation. When guard correctly fastened to the lift truck. DO NOT
the nuts stay tight after an 8-hour check, the make changes to the overhead guard by welding.
interval for checking the torque can be extended to Changes that are made by welding or by drilling
500 hours. Refer to the Table 1 in this section. holes can reduce the strength of the overhead
guard.
Inspect the tires for embedded rocks, glass, wire,
DO NOT weld mounts for lights or accessories to
pieces of metal, holes, cuts, and other damage. See
the leg of the overhead guard. The strength of the
Figure 8. Remove any object that will cause damage.
overhead guard components can be compromised
Check for loose or missing nuts and broken studs.
by welding or heating.
Remove any wire strapping or other material that is
wrapped around the axle to prevent damage to the Make sure the capscrew that holds the vertical
axle seal. See Figure 10. If the wheel and tire has support post that supports the overhead guard is
recently been installed, check to ensure the lug nuts in the correct position and is tight. The overhead
are properly tightened to 135 N•m (100 lbf ft). When guard and support post reinforce one another to
installing, snug all the nuts, then tighten to half the provide protection to the operator.
torque value, then tighten to the full torque value.
Tighten the nuts in a cross pattern to properly seat the Make certain the overhead guard is in place and
wheel to the hub. securely attached to the mast. Make certain that the
operator's guard is installed between the mast and the
Frame and Load Wheels operator's compartment.
Inspect the frame for structural damage and loose/

missing hardware. Make certain all covers are in place
and secured before operating the lift truck. Inspect the
load wheels. Loose or crooked load wheels may
indicate bearing failure. If failure is suspected, raise
the lift truck front end slightly (refer to
How to Put Lift Truck on Blocks) and check that load
wheels are secure on their axles and rotate smoothly.
Repair or replace as necessary.
Safety Labels
WARNING
Safety labels are installed on the lift truck to give
information about possible hazards. It is important
that all safety labels are installed on the lift truck
and can be read. 1. CHECK FOR DAMAGE. REMOVE NAILS,
GLASS, METAL, AND OTHER OBJECTS.
Check that all safety labels are installed in the correct 2. MAKE EDGES SMOOTH
locations on the lift truck. See the Parts Manual or the
Figure 10. Check Tires
Frame 0100YRM1615 for the correct locations of the
safety labels.
19
Forks Check c. If fork enters opening, it is mandatory to

replace it. DANGER OF BREAKING.
Furthermore, a 10% reduction in fork blade
WARNING thickness results in 20% reduction in operating
DO NOT try to correct fork tip alignment by capacity.
bending the forks or adding shims. Replace bent
forks.
Never repair damaged forks by heating or welding.
Forks are made of tempered steel using special
procedures and can be weakened by heating or
welding. Always replace damaged forks as a pair.
1. Inspect forks for cracks and wear. Check that fork

tips are aligned as shown in Figure 11. Check that
bottom of fork is not worn (item 4, Figure 11).
CAUTION
Remove fork latch pins if adding a fork positioner
attachment. Damage to forks and other carriage
components can occur if fork latch pins are not
removed prior to using attachment.
2. Replace any damaged or broken parts that are

used to keep forks locked in position. Fork Tip Alignment Specifications
Standard Fork Lengths Maximum Fork Tip
3. Inspect fork wear. Ensure heel wear is not more
Difference1
than 10% of original thickness. If fork wear is
more than 10%, fork must be replaced or rerated. mm (inch) mm (inch)
Perform fork wear inspection using a BOL256N1
914 (36) 27.00 (1.08)
caliper ruler Yale P/N 550088603 as follows. See
Figure 12. 1067 (42) 32.00 (1.26)
1219 (48) 37.00 (1.44)
a. Determine normal thickness of "N" of fork
using scale or ruler portion of caliper ruler. 1Difference of alignment between fork tips must be no
Measurement has to be done on fork shank more than 3% of the total fork length.
using caliper ruler.
A. HEEL OF FORK (MIN. 90% OF DIMENSION B)
b. Position caliper at end of heel internal radius B. ORIGINAL FORK THICKNESS
(item 4, Figure 11) with opening corresponding
to measured thickness of fork shank in Step a 1. TIP ALIGNMENT (WITHIN 3% OF FORK
above. (e.g. for N 1.75 use N 1.75 opening). LENGTH)
2. CRACKS
This is typically the section of fork where wear 3. MAXIMUM ANGLE 93°
is greatest. Note that opening distance has 4. FORK REMOVAL NOTCH
been reduced by 10% from nominal thickness. 5. CARRIAGE
Figure 11. Fork Check
20
5. Fully lower the carriage. With the forks level

(parallel to the floor), measure the distance from
the floor to the top of forks. The correct distance
is 63.5 mm (2.5 in.).
6. Check chain tension by pushing on both chains at

the same time. When the tension is equal on both
chains, the chain sheave assembly will be level. If
the tension is not the same, adjust the lift chains
so the tension is the same and the fork height is
also correct.
Figure 12. Fork Wear Check
Lift Chain Check

NOTE: The chains must be inspected in the area of
chain that passes over the chain sheave during the
first portion of a lift. Those links will show maximum
wear.
1. Apply a 1/2 capacity load to the forks and raise
approximately 25 mm (1 in.) off the floor. Inspect Pitch Wear Limit
Total length of
the lift chains for wear or damage. A lift chain The maximum
20 links (pitch)
becomes longer when it is worn. If a chain is 3% length of 20
of new chain
longer than a new lift chain, the lift chain must be links
replaced. If a chain scale is available, check the 12.7 mm 254.0 mm 261.6 mm
lift chain as shown in Figure 13. If a chain scale is (0.5 in.) (10.0 in.) (10.3 in.)
not available, measure 20 links of the lift chain. 15.90 mm 317.5 mm 327.0 mm
Compare the measurement with the lengths given (0.63 in.) (12.5 in.) (12.9 in.)
in Figure 13. Lower and remove the load when 19.10 mm 381.0 mm 392.4 mm
complete. (0.75 in.) (15.0 in.) (15.5 in.)
25.4 mm 508.0 mm 523.3 mm
2. Inspect the chain anchors and pins. Replace any (1.0 in.) (20.0 in.) (20.6 in.)
parts that are worn or damaged.
NOTE: THE INSTRUCTIONS FOR MEASURING
3. Completely lower the mast. Check to verify that
CHAIN WEAR ARE SHOWN ON THE CHAIN WEAR
the top of the outer weldment is even
(±1.50 mm (0.06 in.)) with the top of the inner SCALE (YALE® PART NO. 580037684).
mast.
1. CHAIN WEAR SCALE
4. Check chain tension by pushing on both main-lift
Figure 13. Lift Chains Check
chains at the same time.
21
Mast Check CHECKS WITH KEY SWITCH TURNED ON
WARNING WARNING
Always wear the proper protective equipment Make sure the area around the lift truck is clear
including eye protection and petroleum-resistant before moving the lift truck. Always look in the
gloves when handling hydraulic oil. Thoroughly direction that you intend to move the lift truck. Be
wash oil from exposed areas of skin as soon as careful when making the checks.
possible.
The lift truck will self-center the steering tire upon
Never check for leaks by putting hands on startup. Make sure feet are clear of the drive wheel
hydraulic lines or components under pressure. and caster assembly when the key switch is turned
Hydraulic oil under pressure can be injected into to the ON position.
the skin.
The lift truck is equipped with a Static Return to OFF
1. Inspect sliding surfaces for wear or damage. (SRO) circuit that prevents travel of the lift truck if the
Inspect load roller contact surfaces for wear or starting sequence is not correct. The function of the
damage. Inspect all welds for cracks. SRO circuit is to make sure the operator is in the
correct position to operate the controls before the lift
2. Inspect the sheaves, chain anchors, and pins. truck will operate. The starting sequence is as follows:
Replace any parts that are worn or damaged.
1. Stand in the operator compartment and turn the
3. Inspect the mast header hoses and fittings for key switch to the ON position. Stand on the brake
hydraulic leaks. Check the hose cover for cracks switch with the left foot and then depress the
or exposed reinforcement. Check for broken or operator presence switch with the right foot.
defective clamping devices and sheaves. Repair
or replace any damaged components as 2. Move the control handle for forward travel.
necessary.
If the control handle is moved before the operator
Reach, Tilt, and Sideshift stands on the brake switch and depresses the
operator presence switch, and the lift truck moves, the
SRO function is not operating correctly. The lift truck
WARNING must not be operated if the SRO circuit does not
Make sure the key switch is in the OFF position function correctly.
and the key is removed from the switch before
doing this check. Operation
1. Check for cracks at the welds on the reach To travel in the forward or reverse direction:
frames and scissor arms.
1. Make sure a charged battery of the correct
2. Check the frame channel for excessive wear in voltage is installed and connected.
the areas of roller contact. Check the rollers for
wear or damage. 2. Stand in the operator compartment and turn the
key switch to the ON position. Stand on the brake
3. Check the load backrest extension for cracks and switch and then depress the operator presence
damage. Make sure the nuts and bolts for the switch.
load backrest extension are tight.
3. Move the control handle for forward or reverse
travel.
22
door. Visually check the oil level and inspect the

CAUTION hydraulic system for leaks and damaged or loose
components. Refer to Hydraulic System, in
The key switch should be used as the primary
Maintenance Procedures Every500 Hours or 3 Months
means of shutting down the truck. Use the battery
of this section.
power disconnect to shut down the truck only in
an emergency. The hydraulic filter element should be replaced after
the first 150 to 250 hours of service and every 2000
Key Switch - The key switch is a three-position hours or yearly thereafter. See Hydraulic Filter Change
switch. The first position is OFF (marked O). The section for the initial filter change instructions.
second position is ON (marked I). The third position is
spring-loaded and automatically returns the key to the Dash Display
ON position after the key is released. The third
position is not utilized for any functions on this lift The dash display interfaces with the master controller,
truck. The key switch is located to the right side of the control handle, and the traction controller. It is located
battery power disconnect knob. adjacent to the multifunction control handle on fore/aft
stance models and adjacent to the steer tiller on
Hydraulic System sidestance models. The dash display is the primary
message communication to the operator and displays
the truck status and active functions, as well as
WARNING warning and advisory messages. The display is also
Always wear the proper protective equipment the communication display during controller
including eye protection and petroleum-resistant programming and diagnostic operations. The dash
gloves when handling hydraulic oil. Thoroughly display is energized when the key switch is in the ON
wash oil from exposed areas of skin as soon as position and the battery disconnect switch is closed.
possible. An internal backup battery provides memory retention
of the battery indicator and hourmeter readings when
Completely lower all mast components and relieve the battery is disconnected from the truck.
pressure by opening the manual lowering valve
before disassembling any part of the lift pump or Four different performance modes of operation can be
disconnecting any hydraulic hoses. selected. Each mode can change a range or
performance related parameters. The factory settings
The hydraulic oil is hot at normal operating increase operating speeds from slowest (Mode 1) to
temperatures. Be careful when draining the oil. the fastest (Mode 4). Each performance mode is fully
Never check for leaks by putting hands on adjustable and can be adjusted by a supervisor or
hydraulic lines or components under pressure. technician. Upon startup, an arrow will appear beneath
Hydraulic oil under pressure can be injected into the current performance mode. To change the
the skin. performance mode, the operator must have activated
the lift truck with the key switch, must be positioned on
the floor switch, and the brake pedal must be
depressed. To change performance modes, press the
CAUTION numbered button that corresponds to the correct
Protect the hydraulic system from dirt and
performance mode.
contaminants when servicing the hydraulic
system. The dash display has a LCD screen for displaying
truck system information. The display has five indicator
Never operate the pump without the proper
lights for truck function status. There are five number
amount of oil in the hydraulic system. The
keys for password input if the lift truck is equipped for
operation of the hydraulic pump with low oil levels
passwords. Number keys 1-4 are also used for
will damage the pump.
navigating the on-board setup and service menus. The
Visually inspect the floor under and around the lift dash display also contains a battery state-of-charge
truck for oil leaks. Check for proper operation of indicator and is equipped to allow operator selectable
hydraulic controls. If hydraulic controls do not function drive modes. See Figure 14.
properly or if leaks are suspected, turn the key to the
OFF position and open the drive unit compartment
23
Lift System Operation
WARNING
Lower the lift mechanism completely. Never allow
anyone under a raised carriage. DO NOT put any
part of your body in or through the mechanism
unless all parts of the mast are completely lowered
and the key switch is in the OFF position.
Before making any repairs, use chains on the mast
weldments and carriage so they cannot move.
Make sure the moving parts are attached to a part
that does not move.
Always wear the proper protective equipment
including eye protection and petroleum-resistant
gloves when handling hydraulic oil. Thoroughly
wash oil from exposed areas of skin as soon as
possible.
Never check for leaks by putting hands on
hydraulic lines or components under pressure.
Hydraulic oil under pressure can be injected into
the skin.
1. Check for leaks in the hydraulic system. Inspect

A. SIDE-STANCE DASH DISPLAY the hydraulic hoses and tubes. Make sure all of
B. FORE/AFT STANCE DASH DISPLAY
the hydraulic lines are connected correctly and do
Figure 14. Displays not leak. Check for broken or defective clamping
devices. Repair or replace any damaged or
The Battery Discharge Indicator (BDI) uses a bar defective components as necessary.
graph as a fuel gauge for the Battery-State-of-Charge.
As the battery discharges, the bar gets shorted to 2. Check that the controls for the hydraulic functions
show less charge (fuel). The green band near the bar make the functions operate correctly. See the
shows the normal operating range for the battery. The symbols by each of the controls.
yellow band is the area that the battery can still be
3. Slowly raise and lower the mast several times
operated in without damage. This band is yellow to
without a load. The mast components must raise
indicate that the battery is nearing the point of
and lower smoothly in the correct sequence.
discharge when it can be damaged with continued
hard use. The red band indicates the discharge
4. Extend the mast fully. If the mast racks (leans) to
condition when battery damage can occur. When the
either side, the main lift cylinders must be
battery is discharged, no bars will be displayed, an
adjusted. Make note of direction of racking and
LED indicator will illuminate, and truck functions will be
lower the mast. See Figure 15.
in limp mode. Continued operation will cause lift-
interrupt , if enabled, to occur to help prevent battery 5. Lower the mast. The inner mast, intermediate
damage. Lift-interrupt prevents the operator form lifting mast, and the carriage must lower completely.
loads and saves enough battery power for the operator
to move the lift truck to a battery charger.
24
NOTE: Some parts of the mast move at different

speeds during raising and lowering.
6. Raise the carriage 1 m (3 ft), with a capacity load.
The carriage must raise smoothly within the inner
mast. Lower the mast. All moving components
must lower smoothly.
7. With the load lowered, tilt the forks backward and

forward. The forks must tilt smoothly.
8. If the lift system does not operate correctly, the

mast or carriage may require adjustment. See the
section Mast 4000YRM1195.
Multifunction Control Handle

Check that the controls for the lift/lower, extend/retract,
tilt, and sideshift operate as described in the
Operating Manual.
NOTE: Each lift truck does not have all of these
functions. Do the checks for the functions that are on
the lift truck.
If the reach mechanism is retracted, it will be
necessary to extend the mechanism to make the
following checks.
1. If the unit has the optional functions, check for

leaks in the hydraulic system. Check the condition
of the hydraulic hoses and tubes.
2. Slowly extend and retract the forks several times

without a load. The components must extend and
retract smoothly.
3. The reach mechanism must slow near the end of

the reach cycle for a smooth stopping action.
4. The forks must fully retract and stay in the fully 1. MAIN LIFT CYLINDER (LH)
retracted position. 2. FREE-LIFT CYLINDER
3. MAIN LIFT CYLINDER (RH)
5. Repeat Step 2 through Step 4 with a capacity
load on the forks. Figure 15. Mast Racking
6. The controls must operate smoothly.
25
Maintenance Procedures Every500 Hours or 3 Months 8000 YRM 1617
Brake neutral braking or "regen" mode (regenerate power to

the battery using the motion of the truck) slowing the
NOTE: The normal method of stopping the lift truck is truck. The control handle can be pushed in the
through the use of "Plugging" using the control handle. opposite direction of travel to "plug," slowing the truck
A spring-applied, electrically-released brake is as a means of braking. However the brake will not
mounted to the top of the traction motor to hold the lift apply until the truck has come to a stop or unless the
truck stationary when the traction motor is not being unit looses power due to a traction fault.
operated. The brake is nonserviceable and
nonadjustable. Check the brake for proper operation. If Steering System
the brake will not release or fails to apply or will not
When turning the key switch to the ON position, the
hold the lift truck, the brake assembly must be
controller will automatically center the drive tire (and
replaced. When the controller senses the truck has
steered caster if equipped). Check that the steering
come to a complete stop, the brake is applied and acts
system operates smoothly with the turning of the
as a parking brake. When the operator removes his
handle and gives good steering control.
foot from the brake switch, the traction motor will begin
Maintenance Procedures Every500 Hours or 3 Months

NOTE: Certain components on the truck require an Completely lower forks to relieve hydraulic
initial inspection earlier than the prescribed pressure disassembling any part of the lift pump
maintenance schedule to preserve the original or disconnecting any hydraulic hoses.
manufacturer's warranties. Perform the 500 hour/3
The hydraulic oil is hot at normal operating
month inspection at 150 to 250 hours after initial
temperatures. Be careful when draining the oil.
installation of the truck and then follow the scheduled
inspections as listed in the Maintenance Schedule. Never check for leaks by putting hands on
See the notes section after the Maintenance Schedule hydraulic lines or components under pressure.
table. Hydraulic oil under pressure can be injected into
the skin.
NOTE: Do these procedures in addition to the 8-hour
checks.
MASTER DRIVE UNIT CAUTION

NOTE: The master drive unit requires only the contaminants when servicing the hydraulic
addition of the recommended oil to maintain the oil at system.
the proper level. Top off the unit by adding oil slowly.
Allow enough time for the oil to flow through the Never operate the pump without the proper
bearings and fill the reservoir. The correct fill level is at amount of oil in the hydraulic system. The
the bottom of the fill plug hole. Use the lubricant shown operation of the hydraulic pump with low oil levels
in the maintenance schedule. See will damage the pump.
Maintenance Schedule. Lubricate the master drive unit
The hydraulic oil level can be checked by opening the
steer gear in accordance with the maintenance
drive unit compartment door and visually checking that
schedule.
the oil is up to the proper level on the tank as indicated
for the battery box size of the truck. See Figure 16.
HYDRAULIC SYSTEM Make all checks when the oil is at operating
temperature, the carriage is fully lowered, the reach
mechanism is retracted, and the key switch is in the
WARNING
OFF position. See Figure 17 or Figure 18. Add
Always wear the proper protective equipment hydraulic oil only as needed. If the tank is overfilled,
including eye protection and petroleum-resistant hydraulic oil may leak from the breather during
gloves when handling hydraulic oil. Thoroughly operation. Refer to Table 2 for the capacities of the
wash oil from exposed areas of skin as soon as hydraulic tanks used on these models of lift trucks.
possible.
26
8000 YRM 1617 Maintenance Procedures Every500 Hours or 3 Months
1. FILTER HOUSING
2. RETURN FITTING
3. FILL LEVEL (EVEN WITH FLANGE) (21.5 INCH
BATTERY COMPARTMENT ONLY)
4. FILL LEVEL (40.0 mm (1.6 in.) BELOW FLANGE)
(ALL OTHER BATTERY COMPARTMENTS)
5. HYDRAULIC TANK
Figure 16. Tank Fill Level
Table 2. Hydraulic Tank Capacities

368.0 mm 419.0 mm 470.0 mm 546.0 mm
Battery Compartment
(14.5 in.) (16.5 in.) (18.5 in.) (21.5 in.)
26.99 liter 26.99 liter 26.99 liter 30.74 liter
Tank Capacity
(7.13 gal) (7.13 gal) (7.13 gal) (8.12 gal)
19.57 liter 19.57 liter 19.57 liter 23.85 liter
Usable Oil
(5.17 gal) (5.17 gal) (5.17 gal) (6.30 gal)
27
WARNING
Hydraulic oil under pressure can be injected into
the skin.
Inspect all hydraulic hoses and fittings for leaks. Check

for broken or defective clamping devices. Repair or
replace any damaged components as necessary.
Check the condition of the breather cap. See Figure 17
for breather cap location. Clean the breather cap in
solvent. If the breather cap cannot be cleaned so air
will flow through it easily, or it is damaged, replace the
breather cap.
Inspect all hydraulic hoses for kinks. Verify that there
are no crushed, flattened, or twisted hoses. Check for
hard, stiff, or charred hoses. Adjust or replace any
hoses as necessary.
1. RETURN HOSE
2. BREATHER CAP
3. AUXILIARY HOSES
4. LIFT HOSE
5. TANK
6. DRAIN HOSE
7. SUPPLY FITTING
8. SUPPLY HOSE
9. MAIN CONTROL VALVE
10. PUMP PRESSURE HOSE
11. LIFT PUMP AND MOTOR
Figure 18. Hydraulic System ()NDR030DB and

NR035/040DB
HYDRAULIC FILTER ELEMENT CHANGE

Change the hydraulic filter element in the first 150 to
250 hours of service and every 2000 hrs or yearly
thereafter. See Hydraulic Filter Change.
1. BREATHER CAP CASTER ADJUSTMENT

2. TANK
3. FILTER HOUSING Casters must be adjusted periodically. If the caster can
4. AUXILIARY PUMP AND MOTOR no longer be adjusted within specification, check the
5. LIFT PUMP AND MOTOR drive tire wear and replace as necessary. If the spring
pack shows any visible damage, the spring pack
Figure 17. Hydraulic System ()NDR030/035EB and
should be replaced.
NR030/040/045EB
28
Elastomer Spring Adjustment

NOTE: The battery must be installed in the lift truck
with no load on the forks.
1. Ensure the lift truck is on a flat and level floor.
2. Loosen upper and lower stop jam nuts, then turn

capscrews clockwise to clear lower support
housing.
3. Measure the caster spring preload (dimension 3).

See Figure 19.
4. Spring preload measurements (dimension 3)

should be within specifications for your lift truck.
Refer to Table 3.
1. MOUNTING CAPSCREWS
2. SHIMS
3. CASTER SPRING PRELOAD
4. UPPER ADJUSTMENT CAPSCREW
5. UPPER ADJUSTMENT GAP
6. LOWER ADJUSTMENT CAPSCREW
7. LOWER ADJUSTMENT GAP
Figure 19. Caster Adjustment
Table 3. Caster Specifications

Truck Series Battery Spring O.D. Mast Max Fork Dimension Dimension Dimension
Compartment Height "3" "5" "7"
mm (in.) mm (in.) mm mm mm
368.3 and (14.5 and 53 (2.09) Less than 6375 mm 70 to 74 9.5 2 to 4
419.1 16.5) (251 in.)
B295 and E815
368.3 and (14.5 and 53 (2.09) More than 6350 mm 70 to 74 6.5 2 to 4
419.1 16.5) (250 in.)
419.1 (16.5) 53 (2.09) Less than 6375 mm 70 to 74 9.5 2 to 4
(251 in.)
419.1 (16.5) 53 (2.09) More than 6350 mm 70 to 74 6.5 2 to 4
(250 in.)
D861
469.9 and (18.5) and 60 (2.36) Less than 8153 mm 75 to 79 9.5 2 to 4
546.1 (21.5) (321 in.)
469.9 and (18.5) and 60 (2.36) More than 8128 mm 75 to 79 6.5 2 to 4
546.1 (21.5) (320 in.)
29
5. If spring preload measurements are not within

specification, raise the rear of the lift truck
approximately 50 mm (2 in.), loosen the three
mounting capscrews, and add or subtract shims
as necessary.
• Greater than Specification = Add Shims
• Less than Specification = Remove Shims
6. Retighten the mounting capscrews and lower the

rear of the lift truck. Remeasure the spring
preload. If the spring measurement is not within
specification, return to Step 5. If the spring
measurement is within specification, continue to
Step 7.
7. Set the upper adjustment capscrew (see

Figure 19) to the proper gap (dimension 5). Refer
to Table 3.
8. Set the lower adjustment capscrew (see

Figure 19) to the proper gap (dimension 7). Refer
to Table 3.
Spring Pack Replacement 1. UPPER SUPPORT HOUSING

If the spring pack shows any visible damage, the 2. SPRING ASSEMBLY
3. PIN
spring pack should be replaced. 4. RETAINING CAPSCREW
5. LOWER SUPPORT HOUSING
Remove Spring Assembly 6. LOWER ADJUSTMENT CAPSCREW
NOTE: Battery must be installed in truck with no load Figure 20. Caster Spring Removal
on forks.
1. Ensure the lift truck is on a flat and level floor. Replace Spring Pack
1. Remove capscrew and washer from top of spring
2. Disconnect the battery connectors and discharge
assembly. See Figure 21.
the capacitors.
2. Remove spring retainer and spherical bearing
3. Raise the rear of the lift truck approximately
from guide rod.
50 mm (2 in.).
3. Remove upper washer, spring pack, and lower
4. Loosen jam nut and screw in the lower
washer(s) from guide rod.
adjustment capscrew. See Figure 20.
4. Check bushing and replace as necessary.
5. On steered units, remove steer motor to access
the caster spring.
5. Apply a thin coat of antiseize lubricant to guide
rod shaft.
CAUTION 6. Install new bottom washer onto guide rod.
Make sure the spring assembly has free play
before removing the pin. NOTE: Different size elastomer springs are use on
different models. Make sure to use the proper spring
6. Remove retaining capscrew and slide pin from for your model lift truck. Refer to the Parts Manual.
lower support housing. Remove spring assembly.
7. Install new Elastomer Spring onto guide rod.
30
Install Spring Assembly

1. Position spring pack to align with holes in lower
housing.
2. Apply a thin coat of antiseize lubricant to pin and

install.
3. Install retaining capscrew.
4. On steered units, install steer motor as removed.
5. Lower the rear of the lift truck to the floor and

adjust the caster. See
Elastomer Spring Adjustment.
DRIVE TIRE CHECK
WARNING
When the wheels have been installed, check all
1. CAPSCREW wheel nuts after 2 to 5 hours of operation. When
2. WASHER
3. SPRING RETAINER the nuts stay tight after an 8-hour check, the
4. SPHERICAL BEARING interval for checking the torque can be extended to
5. GUIDE ROD 500 hours.
6. BUSHING
7. LOWER WASHER Check to ensure the lug nuts are properly tightened to
8. SPRING PACK 135 N•m (100 lbf ft). Inspect the tires for embedded
9. UPPER WASHER
rocks, glass, wire, pieces of metal, holes, cuts, and
Figure 21. Spring Assemblies other damage. Remove any object that will cause
damage. Check for loose or missing nuts and broken
8. Install new top washer onto guide rod. lugs. Remove any wire strapping or other material that
is wrapped around the axle to prevent damage to the
9. Install spherical bearing and spring retainer onto axle seal. Make sure the drive wheel nuts are tight.
guide rod. When installing the tire and wheel, snug the nuts, then
tighten to half the torque value, then tighten to the full
10. Install washer and capscrew onto spring torque value. Tighten the nuts in a cross pattern to
assembly. properly seat the wheel to the hub.
31
LIFT SYSTEM OPERATION 2. Replace any damaged or broken parts that are
used to keep forks locked in position.
WARNING 3. Inspect fork wear. Ensure heel wear is not more

When working on or near the mast or carriage, see than 10% of original thickness. If fork wear is
Safety Procedures When Working Near Mast. more than 10%, fork must be replaced or rerated.
Perform fork wear inspection using a BOL256N1
Lower the lift mechanism completely. Never allow caliper ruler Hyster P/N 4092984 Yale P/N
anyone under a raised carriage. DO NOT put any 550088603 as follows. See Figure 23.
part of your body in or through the lift mechanism
unless all parts of the mast are completely lowered a. Determine normal thickness of "N" of fork
and the battery is disconnected. using scale or ruler portion of caliper ruler.
Always wear the proper protective equipment Measurement has to be done on fork shank
including eye protection and petroleum-resistant using caliper ruler.
wash oil from exposed areas of skin as soon as b. Position caliper at end of heel internal radius
possible. (item 4, Figure 22) with opening corresponding
to measured thickness of fork shank in Step a
Never check for leaks by putting hands on above. (e.g. for N 1.75 use N 1.75 opening).
hydraulic lines or components under pressure. This is typically the section of fork where wear
Hydraulic oil under pressure can be injected into is greatest. Note that opening distance has
the skin. been reduced by 10% from nominal thickness.
Inspect the header hoses for kinks. Verify that there c. If fork enters opening, it is mandatory to
are no crushed, flattened, or twisted hoses. Check for replace it. DANGER OF BREAKING.
hard, stiff, or charred hoses. Adjust or replace any Furthermore, a 10% reduction in fork blade
hoses as necessary. thickness results in 20% reduction in operating
Check for leaks and test the lift system operation as capacity.
described in the Lift and Tilt System Leaks Check
section. Mast
Forks Check
WARNING
DO NOT work under a raised carriage. Lower the
WARNING carriage or use a safety chain to prevent the
DO NOT try to correct fork tip alignment by carriage from lowering when doing maintenance
bending the forks or adding shims. Replace bent on the mast and lift chains.
forks.
Cleaning solvents can be flammable and toxic and
Never repair damaged forks by heating or welding. can cause skin irritation. When using cleaning
Forks are made of special steel using special solvents, always follow the recommendations of
procedures. Replace damaged forks. Forks are to the manufacturer.
be replaced only in sets and not individually.
1. Inspect forks for cracks and wear. Check that fork

tips are aligned as shown in Figure 22. Check
CAUTION
that bottom of fork is not worn (item 4, Figure 22). DO NOT use steam to clean the lift chains,
sheaves, or load rollers. The sheaves and roller
bearings are sealed and permanently lubricated.
DO NOT use compressed air to clean the bearings.
CAUTION
The air can force the lubricant out of the bearings.
Remove fork latch pins if adding a fork positioner
attachment. Damage to forks and other carriage Lubricate the sliding surfaces and the load roller
components can occur if fork latch pins are not surfaces along the full length of the channels. ,
removed prior to using attachment. Maintenance Schedule, Table 1.
32
NOTE: The load rollers and sheaves have sealed

bearings that do not need additional lubrication.
Figure 23. Fork Wear Check
Lift Chains
Fork Tip Alignment Specifications
Standard Fork Lengths Maximum Fork Tip
Difference1 WARNING
When working on or near the mast or carriage, see
mm (inch) mm (inch) Safety Procedures When Working Near Mast
914 (36) 27 (1.08) located before the 8-hour or daily checks.
1067 (42) 32 (1.26) DO NOT work under a raised carriage. Lower the
carriage or use a safety chain to prevent the
1219 (48) 37 (1.44)
carriage from lowering when doing maintenance
1Differenceof alignment between fork tips must be no on the mast and lift chains.
more than 3% of the total fork length.
Check chains for acceptable stretch first before
1. TIP ALIGNMENT (MUST BE WITHIN 3% performing any service. Chains that are stretched
OF FORK LENGTH) beyond specification should be replaced. Lubricate the
2. CRACKS lift chains with SAE 20 or 30 engine oil or chain and
3. LATCH DAMAGE cable lubricant. The best procedure is to remove the
4. HEEL OF FORK (MUST BE 90% OF chains from the lift truck and soak them in oil.
DIMENSION X)
5. CARRIAGE However, the chains may be lubricated by brushing on
6. LOAD BACK REST EXTENSION oil. Chains within specification that are dirty should be
7. MAXIMUM ANGLE 93° removed, cleaned with solvent, inspected, and oiled
8. FORK REMOVAL NOTCH before reinstalling.
Figure 22. Forks Check
33
Maintenance Procedures Every 2000 Hours or Yearly 8000 YRM 1617
OTHER LUBRICATION silicone spray lubricant. See Electrical System

2200YRM1612. Several grease fittings are also
Lubricate the drive unit compartment door hinges pins present on the lift truck and mast. For a complete list
with SAE 20 or 30 engine oil as needed. Wipe away of lubrication points, refer to , Maintenance Schedule,
excess oil. Control handle buttons should be cleaned Table 1, in this section.
thoroughly and may be lubricated sparingly using a
Maintenance Procedures Every 2000 Hours or Yearly

NOTE: Perform these procedures in addition to the 8- ELECTRIC SYSTEM
hour and 500 -hour checks.
Inspect all visible electrical wiring and terminals when
performing these checks. Repair any areas where
BRAKES
rubbing has frayed wiring.
Check
A spring applied, electrically released brake is
Main Contactor
mounted to the top of the traction motor to hold the lift
truck stationary when the traction motor is not being CAUTION
operated. See Figure 24. The brake is nonserviceable
Cleaning is not necessary. DO NOT use a file on
and nonadjustable. Check the brake for proper
the contacts. DO NOT lubricate the contacts.
operation. If the brake will not release or fails to hold
the lift truck plus a capacity load on a 10% slope The contactor contacts are made of special silver alloy.
[1.0 m rise in 10 m (1.0 ft rise in 10 ft)] with the forks The contacts will normally look black and rough from
facing uphill, the brake assembly must be replaced. normal operation. This condition does not interfere
with the operation of the lift truck. There is no
procedure to clean or lubricate the contacts. Replace
the contacts when the silver alloy is worn away to the
base support metal, when the contacts stick in the
closed position, or will not make contact when the
contactor is closed.
Inspect
1. Turn the key switch to the OFF position and
disconnect the battery. Discharge the capacitors.
See Discharging the Capacitors in this section.
2. Remove the electrical compartment cover located

in the operator compartment.
3. Check the contactor for loose, broken, or

corroded connections at the contactor.
4. Check the mechanical function of the contactor.

Use an insulated tool, such as an electrician's
screwdriver, to manually close the contactor tips.
1. CAPSCREWS (MANUAL RELEASE) Check for looseness or binding of the moving
2. SERVICE PORTS (MANUAL RELEASE) parts of the contactor. The parts should move
3. BRAKE ASSEMBLY freely, but the parts must not be so loose that the
4. ASSEMBLY HOLES movement is sloppy.
Figure 24. Brake
34
8000 YRM 1617 Maintenance Procedures Every 2000 Hours or Yearly
5. Visually check the tips for pitting, burning, or Perform fork wear inspection using a BOL256N1
wear. caliper ruler Hyster P/N 4092984 Yale P/N
550088603 as follows. See Figure 23.
6. Check that the resistance of the contactor coil is
within 32 ±5 ohms. Readings not within a. Determine normal thickness of "N" of fork
specification indicate the following: using scale or ruler portion of caliper ruler.
High Resistance - Corrosion or an open coil Measurement has to be done on fork shank
using caliper ruler.
Low Resistance - Shorted or a burnt coil
b. Position caliper at end of heel internal radius
7. Check the voltage drop across the contactor tips.
(item 4, Figure 22) with opening corresponding
Set the voltage scale of the meter to the lowest
to measured thickness of fork shank in Step a
range, higher than battery voltage (50 volts for a
above. (e.g. for N 1.75 use N 1.75 opening).
36-volt battery, etc.). On SPNO contactors, read
This is typically the section of fork where wear
the voltage across the contactor with the tips
is greatest. Note that opening distance has
open. Battery voltage should drop to zero or near
been reduced by 10% from nominal thickness.
zero as the tips close.
A voltage drop of 2 volts or more across the c. If fork enters opening, it is mandatory to
closed tips indicates a poor contact or high replace it. DANGER OF BREAKING.
resistance. Check for burned or worn tips, Furthermore, a 10% reduction in fork blade
incorrect size, or mismatched tips. Also check for thickness results in 20% reduction in operating
an incorrect gap setting on contactors with capacity.
adjustable point gaps. Repair as necessary. See
Electrical System 2200YRM1612. HYDRAULIC SYSTEM
FORKS, CHECK Drain
WARNING WARNING
DO NOT try to correct fork tip alignment by Always wear the proper protective equipment
bending the forks or adding shims. Replace bent including eye protection and petroleum-resistant
forks. gloves when handling hydraulic oil. Thoroughly
Never repair damaged forks by heating or welding. possible.
Forks are made of special steel using special
procedures. Replace damaged forks. Forks are to Completely lower forks to relieve hydraulic
be replaced only in sets and not individually. pressure before disassembling any part of the lift
pump or disconnecting any hydraulic hoses.
1. Inspect forks for cracks and wear. Check that fork The hydraulic oil is hot at normal operating
tips are aligned as shown in Figure 22. Check temperatures. Be careful when draining the oil.
that bottom of fork is not worn (item 4, Figure 22).
CAUTION Hydraulic oil under pressure can be injected into
Remove fork latch pins if adding a fork positioner the skin.
attachment. Damage to forks and other carriage
components can occur if fork latch pins are not
removed prior to using attachment. CAUTION
2. Replace any damaged or broken parts that are contaminants when servicing the hydraulic
used to keep forks locked in position. system.
Disposal of lubricants and fluids must meet local
3. Inspect fork wear. Ensure heel wear is not more
environmental regulations.
than 10% of original thickness. If fork wear is
more than 10%, fork must be replaced or rerated.
35
The hydraulic oil should be changed every 2000 hours c. Allow time for the oil to gravity feed into the
or yearly. When the hydraulic system components tank.
such as the pump or cylinders have been damaged or
the oil has otherwise been contaminated, the hydraulic d. Close the manual lowering valve.
system should be drained, flushed, and refilled with
new hydraulic oil. See Maintenance Schedule in this e. Retighten the bleed screws at the top of the
section. main lift cylinder shells.
1. Park the lift truck on a level surface and lower the

mast. Turn the key switch to the OFF position,
and attach a DO NOT OPERATE tag to the
control handle. Block the wheels to prevent
unexpected movement.
2. Disconnect the battery power cable connector

from the truck connector located on the right side
of the frame. Pull the battery cable connector
handle to separate the battery connector from the
truck connector.
3. Remove the operator compartment cover and the

drive unit compartment door to access the
hydraulic tank.
4. Remove the breather cap from the top of the tank.
5. Position a suitable oil container with a minimum

capacity of 19 liter (5 gal) next to the lift truck to
drain the oil.
CAUTION
DO NOT cut the hose when removing the wire tie.
6. Locate the drain hose at the bottom of the

hydraulic tank. See Figure 25. Carefully clip the
wire tie securing the hose. Loosen and remove
the hose clamp securing the plug in the end of the
hose. Remove the plug from the hose and drain
the hydraulic oil into the container.
7. Some lift trucks use displacement-type main lift

cylinders, which retain some amounts of oil even
when at rest. Refer to Cylinder Identification.
These cylinders may be further drained to reduce
levels of contaminants left in the hydraulic
system.
1. PLUG
If your truck is equipped with displacement type 2. HOSE
main lift cylinders: 3. ELBOW (WITH CLAMP)
4. TANK
a. Loosen both main lift cylinder bleed screws 1/2 5. WIRE TIE
6. CLAMP
turn.
Figure 25. Drain Hose
b. Open the manual lowering valve.
36
8. Drain the remaining oil from the tank. Place the

plug into the hose and secure with hose clamp as
removed. Coil the drain hose and secure with
wire tie as removed.
9. Inspect the tank. Check for damage to the tank or

hoses. Clean the tank if necessary.
10. Reinstall the breather assembly as removed.
Cylinder Identification
Two main lift cylinders and one free-lift cylinder are
present on all models of this series lift truck. However,
cylinders may be either displacement type or piston
type. Different cylinder types require different hydraulic
oil drain and fill procedures.
The main lift cylinders may be identified by the
presence of a bleed screw near the top of the cylinder
shell on displacement type cylinders. Piston type main
lift cylinders are not equipped with bleed screws. See
Figure 26.
1. TOP OF INTERMEDIATE MAST

2. CYLINDER ROD
3. BLEED SCREW
(INDICATES DISPLACEMENT TYPE)
4. CYLINDER SHELL
Figure 26. Main Lift Cylinder Identification
37
Free-lift cylinders can be identified by the cylinder rod

diameter. Measure the diameter of the free-lift cylinder Table 4. Free-Lift Cylinder Rod Widths
rod to determine your lift truck configuration. See
Type Diameter
Figure 27 and Table 4.
Displacement 73.00 mm (2.87 in.)
Piston 44.40 mm (1.75 in.)
Fill
NOTE: Refer to Capacities and Specifications
8000YRM1618 for the proper hydraulic oil selection.
1. Fill the hydraulic tank to the proper level with new
hydraulic oil. The hydraulic oil should be filled to
the level specified for the battery box
compartment of the truck. DO NOT overfill the
hydraulic tank. See Figure 28.
1. FILTER HOUSING
2. RETURN FITTING
1. CROSSHEAD ASSEMBLY 3. FILL LEVEL (EVEN WITH FLANGE) (21.5 INCH
2. CYLINDER ROD DIAMETER BATTERY COMPARTMENT ONLY)
3. BLEED OR FILL SCREW 4. FILL LEVEL (40.0 mm (1.6 in.) BELOW FLANGE)
4. RETAINER BRACKET (ALL OTHER BATTERY COMPARTMENTS)
5. CYLINDER SHELL 5. HYDRAULIC TANK
6. GLAND
Figure 28. Hydraulic Oil Level
Figure 27. Free-Lift Cylinder Identification
38
2. Install the breather cap. 6 to 8 N•m (53 to 73 lbf in). If the free-lift
cylinder completely lowers before all the air is
3. Determine the types of main lift cylinder and free- expelled, close the bleed screw and return to
lift cylinders used. See Cylinder Identification. Step a. Wipe up the expelled oil and repeat
procedure for the other main lift cylinder.
Main Lift Cylinders
1. Piston-type main lift cylinders do not require Free-Lift Cylinders
bleeding. If your lift truck is equipped with piston- 1. Piston type free-lift cylinders are not bled but do
type main lift cylinders, skip to Free-Lift Cylinders. have an oil chamber that must be filled for
cylinder cushion functions to work properly:
WARNING a. Completely lower the mast and carriage. Turn

Keep clear of the mast when bleeding the the key switch to the OFF position and
cylinders. Mast parts may shift or lower disconnect the battery.
unexpectedly.
b. Slightly open the fill screw on the side of the
Always wear the proper protective equipment free-lift cylinder shell near the gland by turning
including eye protection and petroleum-resistant it counterclockwise to make sure the cylinder is
gloves when handling hydraulic oil. Thoroughly not pressurized. Slowly remove the fill screw
wash oil from exposed areas of skin as soon as and seal.
possible.
NOTE: Use a clean oil can to measure and inject
2. Displacement-type main lift cylinders must be hydraulic oil into the cylinder fill hole.
bled:
c. Measure approximately 150 cc (5 oz) of clean
a. Engage the battery connectors and turn the hydraulic oil and fill the oil chamber through the
key switch to the ON position. fill hole. Fill until all the oil is used or until oil
flows out of the fill hole.
b. Activate the lift function using the operator
controls. Continue until the free-lift cylinder rod d. Install the fill screw and seal and tighten to
extends approximately 150 mm (6 in.) to apply 6 to 8 N•m (53 to 73 lbf in). Wipe up any spilled
pressure to the hydraulic system. oil.
c. Turn the key switch to the OFF position and e. Connect the battery and turn the key switch to
disconnect the battery connectors. the ON position. Completely raise and lower
the mast several times to check for proper
operation. The free-lift cylinder should slow
WARNING smoothly near the end of its stroke. Check the
Use a personnel lift or a ladder to access the bleed hydraulic oil level in the tank and fill as
screws. DO NOT climb on the mast or lift truck. necessary. Replace all covers as removed,
remove blocks from the wheels, and return the
lift truck to service.
CAUTION
DO NOT completely remove the bleed screw. WARNING
Loosen it slowly and gradually.
Keep clear of the mast when bleeding the
NOTE: Use a cloth to wipe up foam and oil as it is cylinders. Mast parts may shift or lower
expelled to minimize spills. unexpectedly.
d. Slightly open the bleed screw of either main lift Never check for leaks by putting hands on
cylinder by turning it counterclockwise until air hydraulic lines or components under pressure.
and/or foam is expelled. Allow air/foam to Hydraulic oil under pressure can be injected into
bleed until clear hydraulic oil is present. Close the skin.
the bleed screw and tighten to
39
2. Displacement type free-lift cylinders must be bled:

WARNING
a. Engage the battery connectors and turn the Always wear the proper protective equipment
key switch to the ON position. including eye protection and petroleum-resistant
b. Activate the lift function using the operator
controls. Continue until the free-lift cylinder rod
possible.
extends approximately 150 mm (6 in.) to apply
pressure to the hydraulic system. Completely lower all mast components and relieve
pressure by opening the manual lowering valve
c. Turn the key switch to the OFF position and before disassembling any part of the lift pump or
disconnect the battery. disconnecting any hydraulic hoses.
The hydraulic oil is hot at normal operating
temperatures. Be careful when draining the oil.
CAUTION
DO NOT completely remove the bleed screw.
NOTE: Use a cloth to wipe up foam and oil as it is CAUTION

expelled to minimize spills. Disposal of lubricants and fluids must meet local
environmental regulations.
d. Slightly open the bleed screw on the side of
the free-lift cylinder shell near the gland by 1. Move the lift truck to a safe, level area and
turning it counterclockwise until air and/or oil completely lower the mast. Turn the key switch to
foam is expelled. Allow air/foam to bleed from the OFF position and attach a DO NOT
the cylinder until clear hydraulic oil is present. OPERATE tag to the control handle. Block the
Close the bleed screw and tighten to drive wheel to prevent unexpected movement.
6 to 8 N•m (53 to 73 lbf in). If the free-lift
cylinder completely lowers before all air/foam 2. Disconnect the battery power cable connector
is expelled, close the bleed screw and repeat from the truck connector located on the right side
Step a. Wipe up the expelled oil. Some of the frame. Pull the battery cable connector
displacement type free-lift cylinders also have handle to separate the battery connector from the
an additional bleed screw located in the end of truck connector.
the cylinder rod. Inspect the cylinder rod where
it emerges from the crosshead. If the rod is 3. Remove the operator compartment cover(s) to
equipped with the additional bleed screw, access the hydraulic tank.
repeat the bleed procedure using the additional
bleed screw. 4. Loosen the four capscrews securing cover to the
hydraulic oil filter housing.
e. Connect the battery and turn the key switch to
the ON position. Completely raise and lower 5. Press the cover down by hand to depress the
the mast several times to check for proper element retainer spring, and remove the four
operation. Repeat the bleed procedure until no capscrews.
air is present when bleeding the free-lift
cylinder. Check the hydraulic oil level in the 6. Remove the cover and spring from housing.
tank and fill as necessary. Replace all covers Check the O-ring seal on the cover for cracks or
as removed, remove blocks from the wheels, deterioration. Replace if damaged. See Figure 29.
and return the lift truck to service.
Hydraulic Filter Change

Replace the filter element after the first 150 to 250
hours of service and every 2000 hours or yearly
thereafter.
40
8000 YRM 1617 Lift and Tilt System Leaks Check
7. Remove element from housing and replace with a

new element.
8. Position the cover and spring to the housing.

Press the cover down by hand to depress the
element retainer spring, and install the four
capscrews. Torque capscrews to
6 N•m (53 lbf in).
9. Engage the battery connectors and remove the

DO NOT OPERATE tag from the control handle.
Remove the drive wheel blocks and test for
proper operation.
Check Hydraulic Strainer

The hydraulic breather cap allows air to enter the
hydraulic tank when the hydraulic oil is pumped out to
the cylinders. When the hydraulic oil returns to the
tank, air is expelled through the hydraulic breather
cap. A filter in the cap protects the hydraulic system
1. HYDRAULIC TANK from particles of dirt and other contaminants. If the
2. COVER filter becomes excessively dirty, air flow can be
3. FILTER
4. PUMP RETURN HOSE restricted, causing pressures and vacuums to build
5. HYDRAULIC FILTER HOUSING inside the tank. If air flow becomes restricted through
6. SPRING the hydraulic breather cap, replace the breather cap.
Keep the hydraulic breather area clean and DO NOT
Figure 29. Cover Removal overfill the hydraulic tank.
Lift and Tilt System Leaks Check

LIFT SYSTEM During the test procedures for the hydraulic
system, fasten the load to the carriage with chains
to prevent it from falling. Keep all personnel away
WARNING from the lift truck during the tests.
When working on or near the mast or carriage, see
Safety Procedures When Working Near Mast. 1. Slowly raise and lower the mast several times
without a load. The mast components must raise
Never allow anyone under a raised carriage. DO
and lower smoothly in the correct sequence. The
NOT put any part of your body in or through the lift
carriage raises first, then the inner mast and
mechanism unless all parts of the mast are
intermediate mast (three-stage, full free-lift mast
completely lowered, the key is removed, and the
only).
battery is disconnected.
Always wear the proper protective equipment NOTE: Some parts of the mast move at different
including eye protection and petroleum-resistant speeds during raising and lowering.
gloves when handling hydraulic oil. Thoroughly 2. The inner mast and the carriage must lower
wash oil from exposed areas of skin as soon as completely.
possible.
Never check for leaks by putting hands on 3. Put a capacity load on the forks, and raise and
hydraulic lines or components under pressure. lower the load several times. Lower the load, and
Hydraulic oil under pressure can be injected into tilt the mast forward and backward several times.
the skin. Check for leaks.
41
Battery Maintenance 8000 YRM 1617
4. Raise the carriage and the load 1 m (3 ft). If the position, there are leaks inside the hydraulic
carriage lowers slowly with the control valve in a system. The maximum speed that the forks are
neutral position, there are leaks inside the allowed to tilt forward when there are internal
hydraulic system. The maximum speed that the leaks in the lift system is 13.0 mm (0.5 in.) per 10
carriage is allowed to lower is 50 mm (2 in.) per minutes (measured at the tilt cylinder). This
10 minutes when the hydraulic oil is 30°C (86°F). maximum speed is measured when the hydraulic
If the oil temperature is 70°C (158°F), the oil is 30°C (86°F). If the oil temperature is
maximum speed that the carriage can lower is 70°C (158°F), the maximum speed is
150 mm (6 in.) per 10 minutes. 39.0 mm (1.5 in.) per 10 minutes.
5. Check the lift cylinder for internal leaks. Remove 2. If the leak rate is greater than specifications,
the load from the forks. Install a gate valve in the remove the load from the forks. Install a gate
supply line between the main control valve and valve between the port at the front of the tilt
the mast. Put a capacity load on the forks again. cylinder and the hydraulic line. Put the load on the
Raise the carriage 1 m (3 ft). Close the gate forks again. Close the gate valve. If the forks tilt
valve. If the carriage or mast weldments lower slowly forward, the cylinder seals are leaking. Be
slowly, the seals in the lift cylinders have leaks. sure to check both tilt cylinders.
Refer to the section Lift Cylinders
4000YRM0481. 3. If the forks do not move, open the gate valve and
check for movement again. If the forks move
6. If the carriage does not move, open the gate forward when the gate valve is open, check for
valve and check for movement again. If the leaks in the hydraulic lines or fittings. If no leaks
carriage lowers when the valve is open, check for are found, the carriage selector valve on the front
leaks in the hydraulic lines or fittings. If no leaks frame of the reach carriage might be damaged.
are found, the lowering solenoid might be Remove the load from the forks.
damaged. Remove the load from the forks.
TILT SYSTEM
1. Put a capacity load on the forks. Slowly tilt the
mast forward. If the forks continue to slowly tilt
forward when the control valve is in a neutral
Battery Maintenance
HOW TO CHARGE BATTERY Batteries generate explosive fumes when they are
being charged. Keep fire, sparks, and burning
material away from the battery charger area. Avoid
WARNING sparks from the battery connections. Charge
If the lift truck was operated with a low battery, batteries only in the special area for charging
check all contactors for welded contacts before a batteries. When the battery is being charged, keep
charged battery is connected. the vent caps clear. The battery charger area must
have ventilation so that explosive fumes are
Make sure the key switch is in the OFF position
removed.
and the park brake is set before connecting the
battery. Disconnect the battery when doing cleaning and
maintenance.
The acid in the electrolyte can cause injury. Use
water to flush the area and make the acid neutral
with a water and soda solution. Acid in the eyes
must be immediately flushed with water
continuously for 15 minutes, then seek medical
attention.
42
8000 YRM 1617 Battery Maintenance
Also see the section Industrial Battery

CAUTION 2240YRM0001 for additional information on the
charging and maintenance of a battery.
Never connect the battery charger plug to the plug
of the lift truck. You can damage the electronic NOTE: Many users have battery chargers that can
controller. Make sure the battery charger voltage is follow a program to automatically charge a battery
the correct voltage for the battery. according to recommendations of the battery
manufacturer. Use the recommendations of the battery
NOTE: Use only battery chargers approved by the manufacturer for charging the battery.
battery manufacturer or dealer.
Correct use of the hydrometer and proper operation of
the battery charger is important. See Figure 30. Follow
the instructions of the charger manufacturer. Never let
the battery discharge below the minimum value given
by the battery manufacturer. A fully-charged battery
will have a specific gravity of 1.265 to 1.310 at
25°C (77°F). Never charge a battery at a rate that will
raise the electrolyte temperature above 49°C (120°F).
Never let a battery stay discharged for long periods.
NORMAL CHARGE: This charge is the charge that is
normally given to a battery that is discharged from
normal service. Many users give this charge at a
regular interval based on usage. This practice will
keep the battery fully charged if the battery is not
discharged below the limit. Always use a hydrometer
to check the battery if the interval charge cycle is used.
Frequent charging of a battery that has a 2/3 or more
charge can decrease battery life. Specific Electrolyte Correction Correct
Gravity Temp. Points Value
EQUALIZING CHARGE: This charge is at a low rate
Reading
and balances the charge in all of the cells. The
equalizing charge is normally given approximately 1.210 31°C (88°F) +0.003 1.213
once a month. It is a charge at a slow rate for 3 to 6 1.210 27°C (81°F) +0.001 1.211
hours in addition to the regular charging cycle.
1.210 25°C (77°F) 0.000 1.210
DO NOT give an equalizing charge more than once a
week. The most accurate specific gravity 1.210 18°C (64°F) -0.004 1.206
measurements for a charged battery will be after an ±0.001 for each 2°C from the 25° base value.
equalizing charge. If the specific gravity difference is
more than 0.020 between cells of the battery after an Figure 30. Battery Check
equalizing charge, there can be a defective cell.
Consult your battery dealer.
43
Battery Maintenance 8000 YRM 1617
HOW TO CHANGE BATTERY Adjust the capscrew legs of the battery stand so
the tops of the rollers are the same height as the
bottom of the battery. Adjust all four capscrew
WARNING legs of the stand so the rollers are level. Install
Make sure the capacity of the crane and spreader the battery puller on the end of the stand at the
bar is greater than the weight of the battery. The center.
weight of the battery is normally shown on the
battery case. The spreader bar must NOT be made 3. Release the ratchet lock and attach the hook to
of metal or it must have insulated straps. the lifting hole of the battery. DO NOT permit
hook to make contact with cell terminals. Make
Batteries are heavy. Use care to avoid injury.
sure the battery cables are not damaged during
The replacement battery must fit the battery area battery removal. Stand on the base of the battery
correctly. Use spacers to prevent the battery from puller, release the ratchet lever, and operate the
moving in the battery compartment. crank to pull the battery onto the battery stand.
Make sure the battery is installed in the proper
direction. Ensure the battery cables are routed in a 4. Make sure the battery voltage and weight of the
manner not to protrude from the battery box replacement battery is correct as shown on the
container except where necessary to connect to nameplate for the lift truck. When a replacement
the truck SB connector. Any excess length cable battery is installed, it must fit the battery
should be secured to the inside dimensions of the compartment correctly. See Table 5. Make sure
battery to prevent pinching or damaging the the battery is in a position so it will be installed to
cables. Replace any damaged cables prior to the rear of the compartment and has clearance
installing the battery in the truck. for installation. Make sure the battery connector
can be connected after installation. DO NOT
Make sure the weight of the replacement battery is damage the battery cables during installation.
within the maximum and minimum weights shown
on the nameplate. 5. Use a spreader bar and crane to lift the battery
Make sure the key switch is in the OFF position from the battery stand.
and the park brake is set before connecting the
battery. 6. Install the battery puller on the lift truck frame at
the center of the battery compartment on the side
opposite the battery stand. See Figure 31.
Release the ratchet lock, pass the hook through
CAUTION the battery compartment, and attach the hook to
Disposal of batteries must meet local the battery lifting hole. DO NOT permit hook to
environmental regulations. make contact with cell terminals. Stand on the
base of the battery puller, release the ratchet
1. Disconnect the battery. See Figure 31. Remove
lever. Operate the crank to pull the battery off the
the battery retainer panels.
stand into the battery compartment.
7. Install the battery retainer plates. Connect the

WARNING battery.
To prevent personal injury and battery movement
that is not expected, the battery must be level 8. Tighten the lock nuts.
when it is moving. Make sure the battery stand is
on a level surface and is aligned and adjusted as 9. Close and lock the traction motor compartment
described in the following procedure. door.
2. Align the battery stand with the battery so the end

of the stand is against the roller frame for the
battery.
44
8000 YRM 1617 Battery Maintenance
A. INSTALLATION B. REMOVAL
1. BATTERY RESTRAINT PANEL 4. BATTER PULLER

2. BATTERY STAND 5. RATCHET LOCK LEVER
3. ROLLERS 6. BATTERY
Figure 31. Change Battery
45
Tires and Wheels 8000 YRM 1617
Table 5. Battery Size Specifications

Battery Maximum Battery Size* Battery Weight
Model Volts Compartment
(Length × Width) Length Width Min. Max.
986.0 × 368.3 mm 986.0 mm 365.00 mm 681 kg 953 kg

NDR030EB, (38.8 × 14.5 in.) (38.8 in.) (14.38 in.) (1500 lb) (2100 lb)
24
NR035/040EB, 986.0 × 419.1 mm 986.0 mm 416.00 mm 726 kg 1033 kg
NDR030DB, (38.8 × 16.5 in.) (38.8 in.) (16.38 in.) (1600 lb) (2275 lb)
NR035/040DB 986.0 × 368.3 mm 986.0 mm 365.00 mm 704 kg 953 kg
(38.8 × 14.5 in.) (38.8 in.) (14.38 in.) (1550 lb) (2100 lb)
36
986.0 × 419.1 mm 986.0 mm 416.00 mm 840 kg 1090 kg
(38.8 × 16.5 in.) (38.8 in.) (16.38 in.) (1850 lb) (2400 lb)
986.0 × 419.1 mm 986.0 mm 416.00 mm 840 kg 1090 kg
(38.8 × 16.5 in.) (38.8 in.) (16.38 in.) (1850 lb) (2400 lb)
NDR035EB, 986.0 × 469.9 mm 986.0 mm 473.00 mm 999 kg 1294 kg
36
NR045EB (38.8 × 18.5 in.) (38.8 in.) (18.62 in.) (2200 lb) (2850 lb)
986.0 × 546.1 mm 986.0 mm 530.00 mm 1135 kg 1362 kg
(38.8 × 21.5 in.) (38.8 in.) (20.88 in.) (2500 lb) (3000 lb)
Compartment width is measured from the sides of the battery compartment. Battery length refers to measures
from the front to the rear of the battery compartment.
*Maximum height for all batteries is 787.0 mm (31.0 in.).
WARNING
The battery must fit the battery compartment so that the battery restraint system will operate correctly.
Use the battery compartment spacers to prevent the battery from moving more than 13.0 mm (0.5 in.) in
any direction.
NOTE: Maximum tolerances are within 13.0 mm (0.5 in.) of the size of the battery compartment. The battery
specification chart shows the maximum battery dimensions that will fit into the battery compartment.
Tires and Wheels

DRIVE TIRE
WARNING
The lifting and carrying of solid tires is not
WARNING
recommended because their weight could be in
Wheels must be changed and tires repaired by excess of 45 kg (100 lb). Where applicable, use a
trained personnel only. Always wear safety wheel or tire dolly to assist in the removal and
glasses. installation of the wheel.
1. Raise the rear of the lift truck as described in
How to Put Lift Truck on Blocks.
46
8000 YRM 1617 Tires and Wheels
5. Carefully apply hydraulic pressure until the wheel

CAUTION hub is forced from the old tire into the new tire.
When properly seated, the new drive tire will be
Check all wheel nuts after 2 to 5 hours of
flush to the outer edge or the inner edge of the
operation: when new lift trucks begin operation
wheel hub. See Figure 33.
and on all lift trucks when the wheels have been
removed and installed. Tighten the nuts if
6. Install the tire and wheel on the hub. Tighten the
required. Tighten the nuts in a cross pattern to
lug nuts to the torque value shown in the
136 N•m (100 lbf ft). When the nuts stay tight for 8
Maintenance Schedule
hours, the interval for checking the torque can be
extended to 500 hours. 7. Raise the lift truck high enough to remove the
blocks. Lower the lift truck to the floor.
2. Remove the wheel nuts that fasten the drive
wheel to the hub. Slide the wheel out from under Table 6. Tires and Wheels
the lift truck. Use the reverse procedure to install
the wheel. Tighten the wheel nuts to Tires and Tire Size
Compound
136 N•m (100 lbf ft) after installation. Wheels
Drive Tire 12 × 5.5 Rubber
HOW TO CHANGE DRIVE TIRE
Drive Tire 12 × 5.5 Polyurethane
NOTE: To change cushion tires, the wheel must be
pressed out of the rim. The proper tools, equipment, Caster 8×2 Polyurethane
and press ring must be used. DO NOT attempt to Load Wheels 5×3 Polyurethane
change tires (rims) or wheels unless you have the
Load Wheels 5×4 Polyurethane
proper tools, equipment, and experience.
1. Remove the drive tire from the lift truck.
2. To remove the tire from the wheel, the correct

tools, equipment, and a press ring must be used
for each size of wheel. Use a press to push the
wheel from the rim and tire.
3. Make sure the wheel hub is the correct size for

the tire. DO NOT mix types of tires, types of tire
treads, or wheels of different manufactures on
any one lift truck. Tire sizes listed in Table 6 are
for the drive tires, load wheels, and caster
wheels.
4. Position the new tire in the press. See Figure 32.

Align the wheel and tire assembly removed from 1. PRESS RING
the truck on top of the new tire. Make certain the 2. OLD TIRE
3. NEW TIRE
wheels are aligned. Make certain the tires are 4. WHEEL HUB
level. Position a press ring on top of the wheel
hub. Figure 32. Position Tire on Wheel
47
Tires and Wheels 8000 YRM 1617
CAUTION
Replace bearings in sets to maintain proper wheel
loading and operation.
2. Inspect the bearings by rotating each caster

wheel. The wheels should have no side-to-side
free play and should turn smoothly. If the wheels
can be moved side to side or do not turn freely,
the bearings should be replaced.
3. Use a punch to tap around the edge of the

bearing cap to work it out of the caster wheel.
4. Unstake the bearing lockwasher from the bearing

lock nut and remove the lock nut and lockwasher.
5. Remove the caster wheel from the axle shaft.
1. SOLID TIRE
2. WHEEL HUB
3. OUTER EDGE
4. PRESS TIRE FLUSH TO THIS SIDE OF WHEEL
Figure 33. 12 × 5.5 Solid Tire Pressed Onto Drive

Wheel
TANDEM LOAD WHEELS

Put the base arms on blocks as described in
How to Put Lift Truck on Blocks. For easier installation,
remove and install one load wheel before removing the
next load wheel. The load wheels are held in the load
arms by the load wheel brackets. Remove the axle
nut, axle, washers, bearings, and load wheel. Remove
the axle sleeve from the load wheel. Pack the new
load wheel with grease. Install the new load wheel,
1. AXLE SHAFT
axle, axle sleeve, bearings, washers, and axle nut. 2. WASHER
See Figure 34. On lift trucks used in freezer 3. BRACKET
applications, apply antiseize lubricant to the load 4. AXLE SLEEVE
wheel axle. 5. BEARING
6. LOAD WHEEL
7. NUT
CASTER WHEELS
Remove Figure 34. Tandem Load Wheels
For the following instructions, see Figure 35.
1. Raise the rear of the lift truck approximately

50 mm (2 in.) to access the caster wheels. Refer
to How to Put Lift Truck on Blocks.
48
8000 YRM 1617 Tires and Wheels
7. Inspect the caster wheel for damage to the

CAUTION bonded wheel surface and cracks in the hub or
Use a hammer and a suitable brass or aluminum wheel material. Replace any wheel that is
driver when removing bearings to avoid damage to damaged, cracked, or has large cracks or large
the bearings and/or caster wheel. chunks of the outside material missing. Replace
wheels in sets if damaged.
The bearings are removed and replaced by
pressing on the outer race of the bearing only. Install
Pressing on the inner race will damage the
bearing.
WARNING
6. Remove the bearing by pressing it from the wheel Cleaning solvents can be flammable and toxic and
hub using a suitable brass or aluminum driver. can cause skin irritation. Wear protection when
handling solvents and always follow the
recommendations of the manufacturer.
1. Clean all parts with solvent and inspect

thoroughly. Replace damaged parts as
necessary.
CAUTION
The bearings are replaced by pressing on the
outer race of the bearing only. Pressing or tapping
on the inner race will damage the bearing.
2. Press new bearings into wheel assemblies. Use a

suitable brass or aluminum driver when installing
bearings to avoid damage to bearings and/or
wheels. See Figure 35. Bearings must be
replaced in sets.
3. Install the caster wheels to the axle shaft.
CAUTION
4. Install the bearing lockwashers and lock nuts onto

the axle shaft.
5. Torque the bearing lock nuts to

1. BEARING CAP
2. BEARING LOCKWASHER 136 N•m (100 lbf ft).
3. BEARING LOCK NUT
4. CASTER WHEEL 6. Ensure the caster wheels rotate freely and
5. AXLE SHAFT smoothly and are securely mounted on the axle
6. BEARING shaft. Stake the bearing lockwashers in place.
Figure 35. Caster Wheels
49
Preparation for Storage 8000 YRM 1617
7. Inspect the caps for damage. Repair or replace

as necessary. Install the caps to the wheels by
tapping around the edge of the caps. Make sure
the caps are properly seated in the hubs.
Preparation for Storage

The following storage procedures are guidelines for 4. Disconnect battery cables from the batteries.
conditions and temperatures above 0°C (32°F). Adjust Apply corrosion preventive to battery terminals.
these procedures to meet local conditions as well as
any expected change in conditions during storage. 5. Put blocks at the front and rear of the drive tire
Determine the amount of preparation necessary for when parked. DO NOT use the parking brake.
storage based on the following:
6. Clean dust and dirt from interior surfaces and
• Length of Storage. Short-term storage is from 1
exterior surfaces. Clean frame to remove sand or
to 6 months. Long-term storage is over 6
months. road salt. Allow frame to air dry.
• Storage Locations. A lift truck stored indoors will 7. If lift truck is parked outside, cover with a tarp or
not require as much external protection as a lift protective material to keep direct sunlight out of
truck stored outdoors.
the operator's compartment and water out of the
controls.
SHORT-TERM STORAGE (1 TO 6
MONTHS) LONG-TERM STORAGE (6 MONTHS OR
LONGER)
CAUTION 1. Complete all short-term storage procedures.
Make sure all caps, lids, and dipsticks are installed
correctly. 2. Wrap or cover all exterior lights and air vents with
moisture barrier paper and tape closed.
1. Check lubricants and fluid levels.
3. Remove the batteries from the lift truck. Put the
2. Masts are to be stored fully lowered. Lubricate batteries in storage. Be sure to follow local fire
any exposed part of all cylinder rods with SAE 30 regulations.
or SAE 40 engine oil.
4. Spray exterior surfaces and frame with
3. Check that all switches and accessories are off. preservative coating.
50
8000 YRM 1617 2/18 (1/16)(7/13)

Periodic Maintenance

Uploaded by

Document Informationclick to expand document information

Document Informationclick to expand document information

Copyright:

Available Formats

Periodic Maintenance

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Periodic Maintenance

Uploaded by

Copyright:

Available Formats

Maintenance

PART NO. 550072991 8000 YRM 1617

©2018 Yale Materials Handling Corp. i

TABLE OF CONTENTS (Continued)

This section is for the following models:

(NDR030DB, NR035/040DB) [B295];

1. OPERATOR COMPARTMENT COVER

Figure 1. Front Frame Panel (Left Side)

NOTE: On right side front frame panels, ensure the

Drive Unit Compartment Door 3. Remove the operator compartment cover.

Caster Wheel Cover

DISCHARGING THE CAPACITORS

2. Disconnect the battery power cable connector

3. Attach a towing strap of adequate capacity to the

NOTE: The parking brake can be manually released

a. Insert two 1/4-20 × 1 (UNC) capscrews into the 1. CAPSCREWS (1/4-20 × 1)

WARNING 4. Raise the lift truck and position solid, one-piece

1. DRIVE AND CASTER WHEELS 2. LOAD WHEELS

Figure 5. How to Put Lift Truck on Blocks

MANUAL LOWERING VALVE

The manual lowering valve is located on the main lift

NDR030DB and NR035/040DB 1. LOWERING CONTROL VALVE

Manual lowering is accomplished by pushing in the Figure 6. Pump (Valve Manifold)

Legend for Figure 7.

A. MANUAL LOWERING VALVE KNOB

Figure 7. Main Control Valve

3. Turn the key switch to the OFF position to stop

5. Check that all switches and accessories are

Preparation for Use

PREPARATION AFTER SHIPMENT 4. Follow the steps in the section

Safety Procedures When Working Near Mast

a. Raise the mast to align the bottom

1. Lower the mast and carriage completely. Press

Legend for Figure 8.

Figure 8. Safety Chains

Figure 9. Maintenance Points

Table 1. Maintenance Schedule

Item Item 1 day/ 3 mo/ 1 yr/ Procedure or Specification

1 Battery X, C1 Check for Full Charge Charge or Change Out

Fluid Level X Check Distilled Water

Restraint X Check Condition Repair as Necessary

Power X Check Operation Repair as Necessary

X=Check C=Change L=Lubricate

Table 1. Maintenance Schedule (Continued)

Item Item 1 day/ 3 mo/ 1 yr/ Procedure or Specification

2 Brake X Check Operation Repair as Necessary

X Hold on Grade Test Capacity Load on 10%

3 Control Handle X Check Operation Repair as Necessary

4 Electrical X Check Operation Repair as Necessary

Contactors X Check Condition Repair as Necessary

5 Forks X X X Check for Damage Replace as Necessary

Guides and X L As Required Multipurpose Grease2

Sideshift X Check Wear Replace as Necessary

6 Dash Display, X Check Operation Repair as Necessary

7 Hydraulic X Visually Inspect for Repair as Necessary

X Check for Proper Repair as Necessary

X Check Level See Table 2