Yale OS030BC, SS030BC Order Selector Workshop Service Manual

Original Illustrated Factory Workshop Service Manual for Yale Order Selector Models OS030BC, SS030BC

Original factory manuals for Yale Forklift Trucks, contains high quality images, circuit diagrams and instructions to help you to operate and repair your truck. All Manuals Printable and contains Searchable Text

Covered models:
    OS030BC
    SS030BC

Format: PDF, 304 Pages
Language: English

Contents:
    1 OPERATING INSTRUCTIONS
        MODEL DESCRIPTION
        OPERATING CONTROLS
        SAFETYAND INFORMATIONAL LABELS
        NAMEPLATE
        SERIAL NUMBER
        MODEL CODE
        TRUCK WEIGHT
        CAPACITY RATING
        SAFETY LABELS
        OPERATING PROCEDURES
        OPERATOR PRE-CHECKSAND INSPECTION
        OPERATOR`S DAILY CHECK LIST
        OPERATING PRECAUTIONS
    2 GENERAL TRUCK AND LUBRICATION SCHEDULE
        MAINTENANCE
        SAFE MAINTENANCE PROCEDURES
        BATTERY OPERATION
        BATTERY INSTALLATION
        WATER ADDITIONS
        CLEANING
        CHARGING THE BATTERY
        CHANGING THE BATTERY
        FORKS
        TETHER LINEAND BELT
        PALLET CLAMP
        HOW TO PUTA LIFT TRUCK ON BLOCKS
        HOW TO RAISE THE DRIVE/ STEER TIRE
        HOW TO RAISE THE LOAD WHEELS .
        LUBRICATION INSTRUCTIONS
        EVERY8 HOURS
        EVERY350 HOURS
        EVERY2000 HOURS
        YALE WARRANTY INFORMATION
        RECOMMENDED SCHEDULES OFMAINTENANCE
        HYDRAULIC OILS
        GEAR OILS
        GREASE
        ANTI-SEIZE LUBRICATING COMPOUND
        TIRES AND WHEELS
        HOW TO CHANGE THE DRIVE/STEER TIRE
        HOW TO CHANGE THE LOAD WHEELS
        HOW TO MOVEA DISABLED LIFT TRUCK
        HOW TO TOW THE LIFT TRUCK
        PRECAUTIONS FOR TRUCKS IN STORAGE
        PRECAUTIONS FOR BATTERIES IN STORAGE
        FASTENERS
        INTRODUCTION
        THREADS, NOMENCLATURE
        STRENGTH IDENTIFICATION
    3 ELECTRICAL SYSTEM
        INTRODUCTION
        GENERAL
        COMPONENT REPAIR AND TESTING
        GENERAL
        MAININTERFACE BOARD (MIB)
        DESCRIPTION/FEATURES
        OPERATION
        PRIORITIES
        REMOVAL
        REPAIR
        INSTALLATION
        CHECKING THE MODEL CODEAND SET-UP STATUS
        CHECKING THE MIB SOFTWARE VERSION
        DEFAULT VALUES
        CUSTOM PROGRAMMING
        MAIN INTERFACE BOARD ADJUSTMENTS
        GENERAL
        MIB SET-UP SEQUENCE
        STEP 1 ENTERING THE SET-UP MODE
        STEP 2 ERASEAND RETURN TO FACTORY DEFAULT VALUES .
        STEP 3 HYDRAULIC POTENTIOMETER SET-UP
        STEP 3B SETTING FUNCTIONS 02, 04 AND 05
        STEP 4 EXITING THE SET-UP MODE
        STEP 5 ADJUSTING MAXIMUM LOWERING RATE
        BELOW24 INCHES
        CHANGING THE MIB VALUES
        INCREASING/DECREASING THE FUNCTION NUMBER
        INCREASING/DECREASING THE FUNCTION VALUE
        MIB SET-UP PROCEDURE
        STEP 1 ENTERING THE SET-UP MODE
        STEP 2 ERASEAND RETURN TO FACTORY DEFAULT VALUES .
        STEP 3 HYDRAULIC POTENTIOMETER SET-UP
        STEP 3B SETTING FUNCTIONS 02, 04 AND 05
        STEP 4 EXITING THE SET-UP MODE
        EXIT WITHOUT SAVING NEW VALUES
        EXITAND SAVE NEW VALUES
        STEP 5 ADJUSTING THE MAXIMUMLOWERING RATE
        BELOW24 INCHES
        MIB FUNCTION DESCRIPTIONS
        MIB CODES
        MIB STATUS CODES
        MIB WARNING CODES .
        MIB FAULT CODES
        STATUS, WARNING AND FAULT CODE TROUBLESHOOTING
        ELECTRICAL SYSTEM COMPONENTS
        CONTACTOR PANEL ASSEMBLY
        DESCRIPTION/FEATURES
        ''''EE'''' CONTACTOR PANEL
        REMOVAL
        INSTALLATION
        CONTACTORS
        TESTING
        REMOVAL
        INSTALLATION
        SUPPRESSORS, DIODESAND RESISTORS
        TESTING
        FUSES
        PROXIMITY SWITCHES
        DESCRIPTION/FEATURES
        OPERATION
        TYPES
        RELAYS
        DESCRIPTION/FEATURES
        24 INCH . .
        150 INCH
        212/272 INCH
        ENABLE
        HOUR METER
        LATCH
        COIL TESTING
        CONTACT TESTING
        REMOVAL
        INSTALLATION
        KEY SWITCH
        REMOVAL
        INSTALLATION
        BATTERY DISCONNECT SWITCH
        REMOVAL
        INSTALLATION
        HORN SWITCH
        REMOVAL
        INSTALLATION
        SIDE GATE SWITCH
        REMOVAL
        INSTALLATION
        ELECTRO-HYDRAULIC PROPORTIONAL VALVES
        OPERATION . .
        TESTING/REMOVAL/INSTALLATION
        REMOVAL/INSTALLATION
        CONTROL HANDLE
        DESCRIPTION/FEATURES
        OPERATION
        DISASSEMBLY
        ASSEMBLY
        TRACTION AND HYDRAULIC POTENTIOMETERS
        TESTING
        INSTALLATIONAND ADJUSTMENT
        BATTERY CHARGE INDICATOR/HOURMETER
        DESCRIPTION/FEATURES
        TESTING
        HOURMETER INPUT
        BRAKE SWITCH INPUTS
        REMOVAL
        INSTALLATION
        ADJUSTMENT (SET-UP)
        VOLTAGE SELECTION
        EV-100LX MOTOR CONTROLLER
        EV-100LX DESCRIPTIONAND OPERATION
        THE SILICON CONTROLLED RECTIFIER (SCR)
        A MOTOR CIRCUIT THAT OPERATES WITH PULSES
        TRACTION CIRCUIT
        THE SCR 1''''OFF CIRCUIT
        INDUCTION CURRENT FROM THE MOTOR
        THE CONTROL CARD
        PULSEMONITOR TRIP (PMT)
        SRO CIRCUIT
        CIRCUIT PROTECTION
        CURRENT LIMIT
        THERMAL PROTECTION
        FILTER (SUPPRESSORS)
        CONTROL CARDADJUSTMENTS (TRACTION CIRCUIT)
        ACCELERATOR CONTROL
        CONTROL CARD
        SEQUENCE OFOPERATION
        STATUS CODES
        CONTROL CARD CONNECTIONS
        HAND SET
        CHECKS AND ADJUSTMENTS, CONTROL CARD
        FUNCTION CODES
        BENCH TESTS
        TESTS-CONTROL CARD INSTALLED INA LIFT TRUCK
        FUNCTION SETTINGS
        GENERAL
        CONNECT, DISCONNECT, AND CHECK THE HAND SET
        CHECKAND ADJUST FUNCTIONS
        ADJUSTING SPEED LIMIT 1
        FUNCTION DESCRIPTIONS
        TRACTION CONTROL CARD (LABEL LETTER TX)
        TABLE FOR FUNCTION VALUE SETTINGS
        TROUBLESHOOTING
        MOTOR MAINTENANCE-GENERAL
        BRUSHAND COMMUTATOR INSPECTION
        NORMAL COMMUTATOR SURFACES
        COMMUTATOR PROBLEMS
        BRUSH REPLACEMENT-TRACTIONAND HYDRAULIC MOTORS
        REMOVAL
        INSTALLATION
        REMOVAL
        INSTALLATION
        REMOVAL
        INSTALLATION
        COMMUTATOR REPAIRS
        TESTS
        DAMAGED FIELDAND ARMATURE
        SHORT-CIRCUIT INAN ARMATURE WINDING
        SHORT-CIRCUIT IN THE ARMATURE
        OPEN CIRCUIT INA FIELD COIL
        SHORT-CIRCUIT INA FIELD COIL
        SHORT-CIRCUIT BETWEEN FIELDAND MOTOR CASE
        BRUSH HOLDER
        WIRING DIAGRAMSAND SCHEMATICS
        WIRING SCHEMATIC - EPS II ....... .
        WIRING DIAGRAM- EPS II ......... . ........ .
        OPTIONS DIAGRAM- EPS II
        WIRING SCHEMATIC - WIRE GUIDANCE II
        WIRING DIAGRAM- WIRE GUIDANCE II
        OPTIONS DIAGRAM - WIRE GUIDANCE II
        WIRING SCHEMATIC - EPS III
        WIRING DIAGRAM - EPS III
        OPTIONS DIAGRAM- EPS III
    4 DRIVE UNIT
        GENERAL
        DESCRIPTION
        REPAIR
        REMOVAL
        DISASSEMBLY
        ASSEMBLY
        BEVEL PINION SHAFT INSTALLATION
        BEVEL GEAR INSTALLATION
        CHECKS AND ADJUSTMENTS
        BACKLASHAND TOOTH CONTACT PATTERN
        AXLE SHAFT BEARING CLEARANCE
        TRUNNION BEARING
        INSTALLATION
        TROUBLESHOOTING
    5 BRAKE SYSTEM
        GENERAL
        DESCRIPTIONAND OPERATION
        BRAKE SWITCH
        ELECTRIC BRAKE-REMOVAL AND DISASSEMBLY
        ELECTRIC BRAKE-ASSEMBLYAND INSTALLATION
        BRAKE SWITCH-REMOVE AND REPLACE
        TROUBLESHOOTING
    6 STEERING SYSTEM - EPS II AND EPS III
        INTRODUCTION
        GENERAL
        DESCRIPTION
        CHECKS AND ADJUSTMENTS
        GENERAL
        CHECKS
        AUTOMATIC CHECKS
        ECM CHECK
        MANUAL CHECKS
        CHECKING THE STEERING SYSTEM
        FOR CORRECT OPERATION
        CHECKING THE STEERING AT MASTHEIGHTS
        CHECKING THE ECM POWER TRANSISTORS
        CHECKING THE STEERING CONTACTOR
        ADJUSTMENTS
        GENERAL......
        SETTING TRUCK CONFIGURATION
        SETTING STEERING RESPONSE
        ADJUSTING R4 TO THE OPERATIONAL MIDPOINT
        ADJUSTING THE STEERING CHAIN CLEARANCE
        CENTERING THE STEER TIRE
        CENTERING THE MDUPOTENTIOMETER
        ADJUSTING R3 FOR STRAIGHT TRAVEL
        ADJUSTING THE TRAVEL SPEEDS
        SLOW SPEED
        REPAIR
        GENERAL
        STEERING GEARMOTOR
        REPLACING THE GEARMOTOR ASSEMBLY
        AND STEERING CHAIN
        STEER WHEEL ASSEMBLY
        REMOVAL AND DISASSEMBLY
        ASSEMBLY AND INSTALLATION
        REPLACE THE MDU POTENTIOMETER
        REPLACE THE ECM
        REPLACE THE COMPLETE MODULE
        REPLACE THE LOGIC BOARD SET
        REPLACE THE ECM POWER TRANSISTORS
        REPLACE THE STEERING CONTACTOR
        TROUBLESHOOTING
        STEERING SYSTEM - EPS ID
        GENERAL
        DESCRIPTION
        CHECKS AND ADJUSTMENTS
        GENERAL
        LED INDICATORS
        DIPSWITCHES
        CHECKS
        CHECKING THE STEERING SYSTEM
        FOR CORRECT OPERATION
        CHECKING SLOW TRAVEL SPEED
        CHECKING HIGH LIFT TRACTION SHUT-OFF
        ADJUSTMENTS
        TACHOMETER ADJUSTMENT
        SENSITIVITYADJUSTMENT ..... .
        FEEDBACK POTENTIOMETER ADJUSTMENT
        SLOW TRAVEL ADJUSTMENT
        STEERING CHAINADJUSTMENT
        REPAIR
        TACHOMETER REPLACEMENT
        FEEDBACK POTENTIOMETER REPLACEMENT
        ELECTRONIC CONTROL MODULE REPLACEMENT
        STEER MOTOR ASSEMBLY AND STEERING CHAIN
        REPLACEMENT
        TYPICAL OPERATING VOLTAGES
        TROUBLESHOOTING
    7 STEERING SYSTEM - WIRE GUIDANCE II
        INTRODUCTION
        GENERAL
        DESCRIPTION
        OPERATION MODES
        WIRE GUIDANCE
        MANUAL STEERING
        HOW TO OPERATE THE WIRE GUIDANCE SYSTEM
        CHECKS AND ADJUSTMENTS
        GENERAL
        CHECKS
        GENERAL
        CHECKING FOR SHORT-CIRCUITS TO THE FRAME
        CHECKS TO THE LIFT TRUCK
        AUTOMATIC CHECKS
        MANUAL CHECKS
        CHECK 01- OPERATOR CONTROLS
        CHECK 02 -STEERING INPUT VOLTAGE
        CHECK 03 - MDUPOTENTIOMETER COARSEAMPLIFIER
        CHECK 04 -MDU CENTERING
        CHECK OS - DIRECTION INPUTS
        CHECKS 06 THROUGH 09 - SENSOR LEVELS
        CHECK 10 -STEERED END SENSOR BALANCE
        CHECK 11- LOAD END SENSOR BALANCE
        CHECK 13 - MEDIUM TRAVEL SPEED
        CHECK 14 -SLOW TRAVEL SPEED
        CHECKING THE OPERATION OF THE SHUT-OFF CIRCUIT
        CHECKING THE STEERING AT MASTHEIGHTS
        CHECKING THE ECM POWER TRANSISTORS
        CHECKING THE STEERING CONTACTOR
        ADJUSTMENTS . .
        GENERAL.
        ADJUSTING RT1 TO THE OPERATIONAL MIDPOINT
        ADJUSTING THE STEERING CHAIN CLEARANCE
        CENTERING THE STEER TIRE
        CENTERING THE MDUPOTENTIOMETER
        ADJUSTING RT2 FOR STRAIGHT TRAVEL
        ADJUSTING THE TRAVEL SPEEDS
        MEDIUM SPEED
        SLOW SPEED
        ADJUSTING SENSORS TO LIFT TRUCK CENTERLINE
        REPAIR
        GENERAL
        STEERING GEARMOTOR
        REPLACING THE GEARMOTOR ASSEMBLY
        AND STEERING CHAIN
        STEER WHEEL ASSEMBLY
        REMOVAL AND DISASSEMBLY
        ASSEMBLY AND INSTALLATION
        REPLACE GUIDANCE SWITCH, INDICATOR AND ALARM
        REPLACE THE MDUPOTENTIOMETER
        REPLACE THE ECM
        REPLACE THE COMPLETE MODULE
        REPLACE THE LOGIC BOARD SET
        REPLACE THE ECM POWER TRANSISTORS
        REPLACE THE STEERING CONTACTOR
        REPLACE THE SENSORS
        TROUBLESHOOTING
    8 HYDRAULIC SYSTEM
        INTRODUCTION
        DESCRIPTION
        LIFT PUMP AND MOTOR
        ELECTRO-HYDRAULIC CONTROL VALVE
        MANUAL LOWERING
        ACCUMULATOR
        FLOW REGULATOR
        FILTER
        TANK
        FREE LIFT CYLINDER
        MAINLIFT CYLINDERS
        VELOCITY FUSES
        SPECIFICATIONS
        LIFT PUMPAND MOTOR
        ELECTRO-HYDRAULIC CONTROL VALVE
        ADJUSTMENTS
        REPAIRS
        LIFT PUMPAND MOTOR
        REMOVAL
        SEAL REPLACEMENT
        INSTALLATION
        HYDRAULIC CONTROL VALVE
        REMOVAL
        INSTALLATION
        DISASSEMBLY
        ASSEMBLY
        HYDRAULIC TANK
        REMOVAL
        DISASSEMBLY .
        INSTALLATION
        TROUBLESHOOTING
    9 MAST
        INTRODUCTION
        DESCRIPTION
        TRIPLEX MAST
        OPERATOR`S COMPARTMENT
        OPERATION-TRIPLEX MAST
        SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
        CHECKS
        CHECK MAST OPERATION
        CHECK FOR LEAKS IN HYDRAULIC SYSTEM
        REMOVEAIR FROM HYDRAULIC SYSTEM
        CHECK LIFT CHAINS
        CLEANING AND INSPECTION
        ADJUSTMENTS
        LOAD ROLLERS
        ADJUST WEAR PLUGS
        LUBRICATE CHAINS
        ADJUST CHAINS
        ADJUST FREE LIFT CHAIN
        ADJUST MAIN LIFT CHAINS
        ADJUST WEAR STRIPS
        ADJUST SPRING WASHERS
        MAINTENANCE
        OPERATOR`S COMPARTMENT
        REMOVAL
        INSTALLATION
        FORKS
        REMOVAL
        INSTALLATION
        PALLET CLAMP
        TRIPLEX MASTASSEMBLY
        REMOVAL
        CLEANING AND INSPECTION
        INSTALLATION
        INNER AND SECONDARY MASTASSEMBLIES
        REMOVAL AND INSTALLATION
        REPLACE HOSEAND CABLE SHEAVES
        REPLACE HOSES
        FREELIFT CYLINDER
        REMOVAL
        INSTALLATION
        MAIN CYLINDERS
        REMOVAL
        INSTALLATION
        DISASSEMBLY OFA LIFT CYLINDER
        ASSEMBLY OFA LIFT CYLINDER
        LOAD ROLLERSAND WEAR PLUGS
        REMOVAL AND INSTALLATION
        TROUBLESHOOTING-MAST
    10 BATTERY AND CHARGING SYSTEM
        GENERAL
        SAFETY TIPS FOR HANDLING INDUSTRIAL TRUCK BATTERIES
        BATTERY TROUBLESHOOTING
        LEAD-ACID BATTERIES
        SPECIFIC GRAVITY
        CHEMICAL REACTION
        HOW TO SELECT THE BATTERY
        VOLTAGE OFA BATTERY
        BATTERY RATINGS
        KILOWATT HOURS
        THE BATTERYAS A COUNTERWEIGHT
        THE NEWBATTERY
        BATTERY MAINTENANCE
        MAINTENANCE RECORDS
        CLEANING THE BATTERY
        ADDING WATER
        SPECIFIC GRAVITY
        TEMPERATURE
        CHARGING THE BATTERY
        TYPES OF BATTERY CHARGES
        DAILY CHARGE
        EQUALIZING CHARGE
        METHODS OF CHARGING
        GRADUAL CHARGE
        MODIFIED CONSTANT VOLTAGE
        TWO-RATE CHARGE
        TROUBLESHOOTING THE CHARGER
        HOW TO KNOW WHEN THE BATTERY IS FULLY CHARGED.
        BATTERY CHARGING AREA
        EQUIPMENT NEEDED
        PRECAUTIONS FOR BATTERIES IN STORAGE
    11 USER SUPPORT INFORMATION
        SERVICE PARTS ORDERING INSTRUCTIONS
        TECHNICAL PUBLICATIONS
        PARTS MANUALS
        OPERATING MANUAL
        OPERATOR TRAINING
        SERVICE TRAINING COURSES
        SERVICE TRAINING MATERIALS
    12 ALPHABETICAL INDEX