Basic Information Identification Make: Yale Model: Reach Truck D849 Series Covered Models: MR14 [D849], MR16 [D849], MR16HD [D849], MR16N [D849], MR20 [D849], MR20HD [D849], MR25 [D849] Codes Series Code: D849 Introduction Market Position Segment: Industrial Material Handling Equipment (Reach Trucks) Key Features Manufacturer: Yale Material Handling Corporation Application: Designed for high-density warehousing and narrow aisle operations Design Philosophy: Emphasis on operator comfort, productivity, and durability Competitive Analysis Market Peers: Competes with reach trucks from manufacturers like Hyster, Crown, Raymond, Mitsubishi, and Komatsu. Manual Details Coverage Areas Primary Focus: Workshop service and repair Page Count Total Pages: 376 Manual Type Type: Original Illustrated Factory Workshop Service Manual Language Language: English Format Format: PDF Download Manual Coverage Systems Covered Powertrain: Reduction gear (Section 9) Hydraulics: Hydraulic system (Section 5) Electrical: Electrical system (Section 4) Chassis: Truck base mechanics (Section 6), Mast assembly mechanics (Section 7), Small fork mast mechanics (Section 8) Braking: Braking system (Section 10) Procedures Included Diagnostics: Diagnostics and measurements (Section 3) Installation: Installation and settings (Section 2) Maintenance: Standard maintenance (Section 11) Rebuilding: Detailed procedures for component disassembly, inspection, repair, and reassembly of major systems like masts, drive units, and hydraulic pumps. Troubleshooting: Systematic fault finding guides for electrical faults, hydraulic system issues, and mechanical malfunctions. Adjustment: Calibration and adjustment of critical systems such as hydraulic pressures, steering sensitivity, and limit switches. Component Replacement: Step-by-step instructions for replacing major components like drive motors, hydraulic pumps, control modules, and mast cylinders. Technical Depth Depth: Comprehensive factory-level repair and diagnostic information Wiring Diagrams: Detailed electrical schematics crucial for troubleshooting and repair of the complex electrical system, including power distribution, control circuits, and sensor inputs. Manual Specifications File Format File Type: PDF Print Quality Printability: Printable Search Features Searchable Text: Yes Visual Aids Image Quality: High quality images Diagrams: Circuit diagrams included Completeness Scope: Complete workshop service manual covering all aspects of operation, maintenance, and repair. Engine Specifications Primary Engine Type: Electric Motor (AC or DC, typically AC for this generation) Performance Traction Motor: Specifications for motor power, voltage, and current draw will vary by model variant (e.g., MR14 vs. MR25). Lift Motor: Specifications for lift motor power and performance characteristics. Fuel System Power Source: Battery system (details on voltage, capacity, and types like lead-acid or optional lithium-ion are crucial and found within the manual). Transmission Standard Drive Transmission: Direct drive electric motor to drive axle with differential. May include reduction gearing. Optional Steering Transmission: Hydrostatic power steering system. Features Regenerative Braking: AC motor technology typically enables regenerative braking, recharging the battery during deceleration. Safety Features Ratings Certification: Adherence to relevant industry safety standards (e.g., ANSI/ITSDF standards for powered industrial trucks). Active Features Operator Presence System: Seat sensor to ensure the truck only operates when the operator is seated. Speed Control: Automatic speed reduction when turning or when mast is elevated to certain heights. Passive Features Overhead Guard: Standard structural protection for the operator. Load Backrest: Standard feature to prevent loads from shifting backward towards the operator. Technology Features Infotainment Operator Interface: Digital display for truck status, error codes, battery level, and operating hours. Driver Assistance Performance Modes: May include adjustable performance settings (e.g., economy, normal, power) to optimize for different applications and battery conservation. Safety Systems: Features like automatic parking brake engagement, speed reduction in turns, and mast interlocks for safe operation. Connectivity Telematics Options: While not explicit in product description, modern Yale trucks often support telematics for fleet management, usage monitoring, and diagnostics. Maintenance Service Intervals Daily Checks: Pre-shift inspection: check hydraulic fluid level, tire condition, forks, mast, battery, controls, brakes, and safety devices. Scheduled Maintenance: Typically involves lubrication, filter changes (hydraulic, possibly cooling if applicable), battery watering (if applicable), and inspection of wear components at regular intervals (e.g., every 250, 500, 1000 operating hours as per manual guidance). Fluid Specifications Hydraulic Fluid: Refer to manual Section 5 for specific ISO viscosity grade and type (e.g., AW hydraulic oil). Lubricants: Grease points require specific types of lithium-based EP grease as detailed in Section 11. Brake Fluid: Typically not applicable for electric trucks as they utilize electric or mechanical parking brakes, but hydraulic systems may use brake fluid for parking brake actuation in some designs. Refer to Section 10. Known Issues Common Wear Items: Fork wear, mast roller wear, hydraulic hose degradation, battery connections, tire wear, control handle wear. Potential Faults: Refer to Section 3 for diagnostic procedures for common faults related to hydraulic, electrical, or drive system performance. Vehicle History Brand Heritage Manufacturer History: Yale is one of the oldest and most respected brands in the material handling industry, with a legacy dating back to 1875. Model Evolution Series Development: The D849 series represents a generation of Yale reach trucks focused on productivity, efficiency, and operator ergonomics, succeeding earlier models and incorporating advancements in AC technology and control systems. Vehicle...