Yale Order Selector OS030BC, SS030BC Workshop Service Manual

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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