Yale High Lift Order Selector 3000: OS030EA Workshop Service Manual

Original Illustrated Factory Workshop Service Manual for Yale High Lift Order Selector 3000.

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:
OS030EA

Format: PDF, 191 Pages
Language: English

Contents:
1 OPERATING INSTRUCTIONS
    GENERAL
    PRE-OPERATING CHECK
    OPERATING THE TRUCK
    OPERATORS MANUAL
    BATTERY CONNECTOR AND QUICK DISCONNECT
    ON-OFF KEY SWITCH
    STEERING WHEEL
    BRAKING
    LIFT/LOWER CONTROL KNOB
    PICK-UP PALLET
    BATTERY DISCHARGE INDICATOR
    CAUTION TO THE OPERATOR
    HINTS FOR SAFE MAINTENANCE
2 GENERAL TRUCK & LUBRICATION SCHEDULE
    GENERAL
    BATTERY
    LUBRICA TION
    DRIVE UNIT CAPACITY
    HYDRAULIC TANK CAPACITY
    RECOMMENDED SCHEDULE OF PREVENTATIVE MAINTENANCE
    GREASE
    GEAR OILS
    HYDRAULIC FLUIDS
    INTRODUCTION— THREADED FASTENERS
    CONVERSION TABLE
    DRIVE UNIT COMPARTMENT DOORS
    DRIVE UNIT COMPARTMENT COVER
    FLASHING LAMP ASSEMBLY
    BATTERY ROLLERS
    BATTERY CONNECTOR SERVICE
    BATTERY RETAINERS
    BATTERY RETAINERS WITH SPACER PLATE
    WINDSHIELD
    PALLET CLAMP
3 ELECTRICAL SYSTEM
    GENERAL
    TRANSISTOR MOTOR CONTROLLER
    OPERATION
    CHECKS, ADJUSTMENTS AND REPAIRS
    CHECKING CONTACTOR COIL
    CHECKING TRANSISTOR CONTROLLER
    CHECKS WITH CONTROLLER INSTALLED
    ACCELERA TOR POTENTIOME TER
    ADJUSTMENTS
    REPLACING CONTROLLER
    TROUBLESHOOTING
    CONTACTOR AND ELECTRICAL PANELS
    CHECKS AND ADJUSTMENTS
    CONTROL AND POWER FUSES
    CONTACTORS—GENERAL
    TESTING CONTACTORS
    CONTACTORS
    CONTACTOR-REMOVE AND INSTALL
    CONTACTOR—DISASSEMBLY AND ASSEMBLY
    RELA YS-GENERAL
    TES TING RELA Y-CR1
    TESTING RELA Y—CR2
    RELAYS—REMOVAL AND INSTALLATION
    TESTING DIODE BLOCK
    REPLACING DIODE BLOCK
    TESTING POWER STEERING SOLENOID
    REPLACING SOLENOID
    ACCELERATOR POTENTIOMETER-REMOVAL AND INSTALLATION
    FORWARD AND REVERSE SWITCHES—REMOVAL AND INSTALLATION..
    LIFT AND LOWER SWITCHES—REMOVAL AND INSTALLATION
    TROUBLESHOOTING ACCELERATOR SWITCH
    HORN SWITCH-REMOVAL AND INSTALLATION
    INSTRUMENT PANEL-REMOVAL AND INSTALLATION
    KEY SWITCH—REMOVAL AND INSTALLATION
    POWER DISCONNECT SWITCH-REMOVAL AND INSTALLATION
    STEERING INDICATOR GAUGE-TESTING
    STEERING INDICATOR GAUGE-REMOVAL AND INSTALLATION
    VOLTMETER (STANDARD)-REMOVAL AND INSTALLATION
    BATTERY DISCHARGE INDICATOR (OPTIONAL)—
    REMOVAL AND INSTALLATION
    BATTERY DISCHARGE INDICATOR
    RESET AND DISCHARGE ADJUSTMENTS
    SLACK CHAIN INDICATOR LIGHT—REMOVAL AND INSTALLATION
    FOOT SWITCH-REMOVAL AND INSTALLATION
    LOOSE CHAIN SWITCH—REMOVAL AND INSTALLATION
    LIMIT SWITCH-REMOVAL AND INSTALLATION
    Continued
    DRIVE AND HYDRAULIC PUMP MOTORS
    DRIVE MOTOR INSPECTION
    DRIVE MOTOR-BRUSH REMOVAL AND INSTALLATION
    (MOTOR INSTALLED)
    DRIVE MOTOR BRUSH HOLDER-REMOVAL AND INSTALLATION
    (MOTOR INSTALLED)
    DRIVE MOTOR-REMOVAL AND INSTALLATION
    DRIVE MOTOR-DISASSEMBLY AND ASSEMBLY
    HYDRAULIC PUMP AND POWER STEERING MOTORS
    MAINTENANCE INSTRUCTIONS
    BRUSH REPLACEMENT-HOIST PUMP MOTOR
    HOIST PUMP MOTOR-REMOVAL AND INSTALLATION
    HOIST PUMP MOTOR DISASSEMBLY AND ASSEMBLY
    POWER STEERING MOTOR—REMOVAL AND INSTALLATION
    BRUSH REPLACEMENT-POWER STEERING MOTOR
    POWER STEERING MOTOR—DISASSEMBLY AND ASSEMBLY
    SCHEMATIC
    WIRING DIAGRAM—DRIVE UNIT COMPARTMENT
    WIRING DIAGRAM—OPERATORS COMPARTMENT
    WIRING DIAGRAM-OPTIONAL FAN AND LIGHTS
    WIRING DIAGRAM-OPTIONAL BATTERY INDICATOR GAUGE
4 DRIVE UNIT ASSEMBLY
    DRIVE UNIT-GENERAL
    DRIVE UNIT-GENERAL
    DRIVE UNIT SPECIFICATIONS
    DRIVE UNIT-REMOVAL
    DRIVE UNIT-DISASSEMBLY
    CLEANING AND INSPECTION
    DRIVE UNIT-ASSEMBLY
    DRIVE UNIT TRUNNION BEARING-DISASSEMBLY
    DRIVE UNIT TRUNNION BEARING-ASSEMBLY
    LUBRICA TION
    RECOMMENDED SPECIFICATIONS
    DRIVE UNIT-INSTALLATION
    DRIVE WHEEL-REMOVAL AND INSTALLATION
    TROUBLESHOOTING CHART
5 BRAKE SYSTEM
    GENERAL
    DESCRIPTION-ELECTRIC BRAKE
    DESCRIPTION—BRAKE SWITCH
    ELECTRIC BRAKE-REMOVAL AND DISASSEMBLY
    ELECTRIC BRAKE—ASSEMBLY AND INSTALLATION
    BRAKE SWITCH-REMOVE AND REPLACE
    TROUBLESHOOTING
6 STEERING SYSTEM
    GENERAL
    DESCRIPTION
    CHECKS AND ADJUSTMENTS
    CHECKS
    ECM
    ECM POWER TRANSISTORS
    STEERING SYSTEM
    SLOW SPEED TRAVEL
    HIGH LIFT TRACTION SHUT-OFF
    STEERING CONTACTOR
    A DJUSTMENTS-GENERAL
    MULTI-TURN POTENTIOMETER
    STEERING INPUT BALANCE (R4)
    STRAIGHT TRAVEL
    SLOW TRAVEL
    STEERING CHAIN
    REPAIRS
    STEERING MECHANISM-REMOVAL AND DISASSEMBLY
    STEERING MECHANISM—ASSEMBLY AND INSTALLATION
    STEERING CONTA C TOR-REPLACEMENT
    DRIVE UNIT POTENTIOMETER—REPLACEMENT
    ECM-REPLA CEMENT
    LOGIC BOARD—REPLACEMENT
    ECM POWER TRANSISTOR—REPLACEMENT
    GEARMOTOR ASSEMBLY AND STEERING CHAIN-REPLACEMENT.
    TROUBLESHOOTING
7 MASTS
    INTRODUCTION
    MAST WELDMENTS
    OPERATOR PLATFORM
    DESCRIPTION— TWO-STAGE MAST
    OPERATION
    DESCRIPTION-THREE-STAGE MAST
    OPERATION
    MAINTENANCE
    ADJUSTMENTS-TWO-STAGE AND THREE-STAGE MASTS
    LOAD ROLLERS
    WEAR PLUG ADJUSTMENT-MAST
    CHAIN ADJUSTMENT— GENERAL
    REPAIRS— TWO-STAGE MASTS
    FORKS-REMOVAL AND INSTALLATION
    HOSES-REPLACE
    HOIST CHAINS—REMOVAL AND INSTALLATION
    CHAIN SHEAVE—REMOVAL AND INSTALLATION.
    MAST ASSEMBLY-REMOVAL
    OPERATOR PLATFORM—REMOVAL AND INSTALLATION
    MAIN CYLINDER-REMOVAL AND INSTALLATION
    LOAD ROLLERS AND NEAR PLUGS-REMOVAL AND INSTALLATION
    INNER MAST-REMOVAL AND INSTALLATION
    MAST ASSEMBLY—INSTALLATION
    REPAIRS-THREE-STAGE MASTS
    FORKS-REMOVAL AND INSTALLATION
    HOSES—REPLACE
    HOIST CHAIN—REMOVAL AND INSTALLATION
    CHAIN SHEAVES—REMOVAL AND INSTALLTION
    MAST ASSEMBLY— REMOVAL
    OPERATOR PLATFORM—REMOVAL AND INSTALLATION
    MAIN CYLINDER—REMOVAL AND INSTALLATION
    LOAD ROLLERS AND WEAR PLUGS—REMOVAL AND INSTALLATION ..
    INNER AND INTERMEDIATE MAST—REMOVAL AND INSTALLATION.
    MAST ASSEMBLY-INSTALLATION
    INTRODUCTION-HOIST CYLINDERS
    VELOCITY FUSES
    FLOW REGULATORS (ALL MODELS)
    HOIST CYLINDER (PISTON TYPE)— DISASSEMBLY
    HOIST CYLINDER—ASSEMBLY
    TROUBLESHOOTING
8 HYDRAULIC SYSTEM
    INTRODUCTION
    DESCRIPTION—HYDRAULIC SYSTEM
    PUMP
    RELIEF VALVE
    CHECK VALVE
    SOLENOID VALVE
    FLOW CONTROL VALVE
    VELOCITY FUSES
    ACCUMULATORS
    RELIEF VALVE ADJUSTMENT
    HYDRAULIC PUMP-REPAIRS
    HYDRAULIC PUMP—REMOVAL
    SEAL REPLACEMENT
    HYDRAULIC PUMP—INSTALLATION
    HYDRAULIC TANK
    ACCUMULATOR SERVICE AND MAINTENANCE
    SERVICING
    PRECHARGING
    ACCUMULATOR-REMOVAL AND INSTALLATION
    TROUBLESHOOTING
    HYDRA ULIC S YS TEM SPECIFICA TIONS
9 BATTERY AND CHARGING SYSTEM
    INTRODUCTION
    GENERAL
    SAFETY PRECAUTIONS
    LEAD-ACID BATTERIES
    SPECIFIC GRA VITY
    HOW TO SELECT THE BATTERY
    VOLTAGE OF A BATTERY
    THE BATTERY AS A COUNTERWEIGHT
    BATTERY RATINGS
    KILOWATT-HOURS
    BATTERY MAINTENANCE
    THE NEW BATTERY
    MAINTENANCE RECORDS
    CLEANING THE BATTERY
    ADDING WATER
    THE HYDROMETER
    BA TTER Y TEMPERA TURE
    CHARGING THE BATTERY
    TYPES OF BATTERY CHARGES
    METHODS OF CHARGING
    TROUBLESHOOTING THE CHARGER
    HOW TO KNOW WHEN A BATTERY IS FULLY CHARGED
    BATTERY CARE
    BATTERY CHARGING AREA
    EQUIPMENT NEEDED
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