Yale Order Selector OS030BC, SS030BC Workshop Service Manual

Original Illustrated Factory Workshop Service Manual for Yale Order Selector Type OS, SS.

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
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