Model:
D849 Reach Forklift Truck
Product Name:
YALE D849 REACH FORKLIFT Truck Workshop Service Manual PDF Download
Model Codes:
MR14, MR16, MR16N, MR16HD, MR20, MR20HD, MR25
Target Audience:
Forklift maintenance technicians, service engineers, fleet managers, and experienced DIY mechanics responsible for maintaining and repairing Yale D849 Reach Forklift Trucks.
Value Proposition:
Provides factory-level repair and service information, enabling cost-effective maintenance and accurate diagnostics, crucial for minimizing downtime and ensuring operational efficiency of the forklift fleet. Acts as a primary resource, mirroring the data used by authorized service centers.
Manual Benefits:
Contains detailed illustrations, step-by-step instructions, and necessary diagrams/pictures. Enables users to perform repairs and maintenance themselves, saving on labor costs. Facilitates accurate troubleshooting and component identification.
Systems Covered:
Electrical System, Controls System, Traction Module (ACE2), Measuring System, Parameter Acquisition, Truck Functions, Speed Reduction, Braking System, Steering System, Fork Lifting/Lowering, Acceleration/Deceleration Ramps, Hydraulic Functions (including auxiliary functions, fork self-centring), Hydraulic System (distributor, pressure relief valve, solenoid valve, cylinders, lift pump, pipes), Wheels & Tyres, Battery Block, Traction Motor, Steering Motor, Retractable Carriage, Mast Assembly System, Small Fork Mast Mechanics, Reduction Gear System, Frame, Cab, Roof Assembly
Procedures Included:
Installation and Settings, Truck Assembly, Diagnostics and Measurements, Tester Menu Operations, Warning Memorization, Parameter Acquisition Procedures, Truck Functions Operation, Speed Reduction Configuration, Braking System Servicing, Steering System Maintenance, Fork Lifting/Lowering Adjustments, Acceleration/Deceleration Ramp Tuning, Hydraulic Functions Servicing, Auxiliary Functions Configuration, Fork Self-Centring Calibration, Hydraulic System Repair (distributor dismantling, pressure relief valve service, solenoid valve replacement, cylinder servicing, lift pump system maintenance, hydraulic pipe replacement), Wheel and Tyre Maintenance, Battery Block Servicing, Traction Motor Repair, Steering Motor Repair, Retractable Carriage Servicing, Steering System Mechanics, Mast Assembly Repair, Small Fork Mast Mechanics, Reduction Gear System Servicing, Frame, Cab, and Roof Assembly Procedures
Estimated Pages:
Not explicitly stated, but comprehensive workshop manuals typically range from 500 to 1500+ pages.
Type:
Workshop Service Manual / Repair Manual
Language:
English (implied by technical terms and common manual language)
Delivery Format:
PDF Download, provided in ZIP format
Primary Systems:
Hydraulic System, Electrical System, Control System, Powertrain (Traction Motor, Reduction Gear), Steering System, Mast System, Braking System, Operator Interface/Controls
Repair And Maintenance:
Detailed troubleshooting guides, diagnostic procedures using specialized testers (ACE2 Traction Module), component testing, repair procedures for all major mechanical and electrical systems, maintenance schedules, fluid specifications, lubrication points, and replacement procedures for wear items.
Depth Of Information:
Comprehensive. Covers everything from basic installation and settings to advanced diagnostics, system calibration, component disassembly and reassembly, and detailed electrical wiring diagrams. Designed for both experienced mechanics and knowledgeable DIY users.
Required Software:
Adobe Acrobat Reader, WinZip or WinRAR (for extraction)
Printability:
High quality, printable. Designed for users to print specific pages as needed.
Binding:
Digital (PDF format, user printable)
Paper Type:
N/A (Digital format)
Description:
The manual focuses on the drive and lift systems of electric forklift trucks. Specific electric motor specifications (type, power rating, voltage) would be detailed within the 'Traction Motor' and 'Steering Motor' sections.
Operational Parameters:
The manual covers parameters related to motor performance, hydraulic pump output, and system pressures. Specific torque or RPM figures for the electric motors and hydraulic pump would be detailed where relevant to troubleshooting or repair.
Power Source:
Electric. The 'Battery Block' section covers battery maintenance and system integration. No internal combustion engine fuel system details are applicable.
Type:
Electric Drive System, likely AC or DC traction motor driving a reduction gearbox. The 'Reduction Gear System' section details its mechanics and servicing.
Features:
The manual covers features like 'Speed Reduction' and 'Acceleration / Deceleration Ramps' which are electronically controlled aspects of the drivetrain performance.
Control Systems:
Integral to the 'Controls System' and 'ACE2 Traction Module', managing power delivery, speed control, and regenerative braking functions.
Safety Features Overview:
The manual implicitly covers safety through detailed operating procedures, correct assembly, and fault diagnostics that prevent hazardous situations. Specific safety system component details would be found within relevant electrical and hydraulic sections.
Operational Safety:
Speed reduction functions, controlled acceleration/deceleration, and proper hydraulic system operation contribute to safe operation. The manual's diagnostic and measurement sections are key to ensuring these systems function correctly.
Structural Safety:
The 'Frame, Cab, Roof Assembly' section covers the structural integrity of the operator compartment. Mast assembly and fork mechanics also relate to safe load handling.
Operator Interface:
The 'Standard Display' section details the operator's control panel and information readouts, providing operational status and diagnostic alerts. Control levers, buttons, and display indicators are key elements.
System Features:
Features like 'Fork Self-Centring', controlled 'Acceleration / Deceleration Ramps', and the integrated 'Controls System' enhance operational precision and ease of use, reducing operator fatigue and errors.
Diagnostic Tools:
The manual's focus on the 'ACE2 Traction Module' and 'Tester Menu' indicates sophisticated electronic control and diagnostic capabilities, likely involving a direct connection to the truck's onboard computer system.
Recommended Checks:
The manual would contain detailed recommended service intervals for hydraulic fluid changes, lubrication, filter replacement, battery checks, and electrical system inspections, tailored to operational hours or calendar time.
Hydraulic Fluid:
Specific hydraulic fluid types and viscosity grades required for optimal system performance and longevity would be listed. Typical industrial hydraulic oils (e.g., ISO VG 32, 46) are common, but the manual will specify the exact Yale-approved fluid.
Lubricants:
Various grease types and lubricating oils for different components (e.g., mast rollers, steering linkages, gearbox) will be specified with their appropriate application points and intervals.
Common Wear Items:
Based on typical reach truck usage, common wear items addressed in such manuals include hydraulic cylinder seals, mast rollers, steer axle components, traction motor brushes (if applicable), and wear pads within the mast system.
Diagnostic Approach:
The manual emphasizes a systematic approach using diagnostic tools (like the ACE2 Traction Module), error code interpretation, and measurement of electrical signals and hydraulic pressures to pinpoint faults.
