Yale OS030EB Order Picker B801 Service Repair Manual

S.N: B801
Yale Model: OS030EB
1 OPERATING INSTRUCTIONS
MODEL DESCRIPTION
OPERATING CONTROLS
SAFETY AND INFORMATIONAL LABELS
CAPACITY PLATE
SERIAL NUMBER
MODEL CODE
TRUCK WEIGHT
CAPACITY RATING
SAFETY LABELS
OPERATING PROCEDURES
OPERATOR PRE-CHECKS AND INSPECTION
OPERATORS 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 LINE AND 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
EVERY 8 HOURS
EVERY 350 HOURS
EVERY 2000 HOURS
YALE WARRANTY INFORMATION
RECOMMENDED SCHEDULES OF MAINTENANCE
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
GENERAL
TRANSISTOR MOTOR CONTROLLER
OPERATION
CHECKS, ADJUSTMENTS AND REPAIRS
CHECKING CONTACTOR COIL
CHECKING TRANSISTOR CONTROLLER
CHECKS WITH CONTROLLER INSTALLED
ACCELERATOR POTENTIOMETER
ADJUSTMENTS
REPLACING CONTROLLER
TROUBLESHOOTING
CONTACTOR AND ELECTRICAL PANELS
CHECKS AND ADJUSTMENTS
CONTROL AND POWER FUSES
CONTACTORS-GENERAL
TESTING CONTACTORS
CONTACTOR-REMOVE AND INSTALL
CONTACTOR-DISASSEMBLY AND ASSEMBLY
RELAYS-GENERAL
RELAYS-REMOVEAND INSTALLATION
TESTING DIODE BLOCK
REPLACING DIODE BLOCK
TESTING POWER STEERING SOLENOID
REPLACING POWER STEERING SOLENOID
ACCELERATOR POTENTIOMENTER-REMOVAL AND INSTALLATION . .
FORWARD AND REVERSE SWITCHES-REMOVAL AND INSTALLATION
LIFTAND LOWER SWITCHES-REMOVAL AND INSTALLATION
TROUBLESHOOTING ACCELERATOR SWITCH
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-REMOVAL AND INSTALLATION …
BATTERY DISCHARGE INDICATOR
RESETAND DISCHARGEADJUSTMENTS
SLACK CHAIN INDICATOR LIGHT-REMOVAL AND INSTALLATION …
FOOT SWITCH-REMOVAL AND INSTALLATION
LOOSE CHAIN SWITCH-REMOVAL AND INSTALLATION
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 BRAKEADJUSTMENT
ELECTRIC BRAKE-ASSEMBLYAND INSTALLATION
BRAKE SWITCH-REMOVE AND REPLACE
TROUBLESHOOTING
6 STEERING SYSTEM
GENERAL
DESCRIPTION
CHECKS AND ADJUSTMENTS
GENERAL
CHECKS
DIPSWITCHES
LED INDICATORS
CHECKING THE STEERING SYSTEM
FOR CORRECT OPERATION
CHECKING SLOW TRAVEL SPEED
CHECKING HIGH LIFT TRACTION SHUTOFF
ADJUSTMENTS
GENERAL
TACH GENERATOR STEERING SYSTEM
TACH GENERATOR ADJUSTMENT
SENSITIVITY ADJUSTMENT
FEEDBACK POTENTIOMETER ADJUSTMENT
SMART STEERING SYSTEM
COMMAND POTENTIOMETER ADJUSTMENT
FEEDBACK POTENTIOMETER ADJUSTMENT
STEERING CHAINADJUSTMENT
REPAIR
TACH GENERATOR STEERING SYSTEM
TACH GENERATOR REPLACEMENT
SMART STEER STEERING SYSTEM
COMMAND POTENTIOMETER REPLACEMENT
FEEDBACK POTENTIOMETER REPLACEMENT
ELECTRONIC CONTROL MODULE REPLACEMENT
STEER MOTORASSEMBLY 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 – MDU POTENTIOMETER COARSEAMPLIFIER .
CHECK 04 – MDU CENTERING
CHECK 05 – 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 SHUTOFF CIRCUIT.
CHECKING THE STEERING AT MAST HEIGHTS
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 MDU POTENTIOMETER
TRAM ADJUSTMENTS
TRAM STEER ADJUSTMENT VERIFICATION
TRAM STEER ADJUSTMENT
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
MAST LIFTAND LOWER
MANUAL LOWERING
ACCUMULATOR
FLOW REGULATOR
FILTER
TANK
MAIN LIFT CYLINDERS
VELOCITY FUSES
SPECIFICATIONS
REPAIRS
LIFT PUMP AND MOTOR
REMOVAL
SEAL REPLACEMENT
INSTALLATION
HYDRAULIC TANK
REMOVAL
DISASSEMBLY
INSTALLATION
TROUBLESHOOTING
9 MAST
INTRODUCTION
DESCRIPTION
TRIPLEX MAST
OPERATION-TRIPLEX MAST
SIMPLEX MAST
OPERATION-SIMPLEX MAST
OPERATOR`S COMPARTMENT
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 PLATFORM LIFT CHAINS
ADJUST MAIN LIFT CHAINS
ADJUST WEAR STRIPS
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 HOSES
MAIN CYLINDERS
REMOVAL
INSTALLATION
DISASSEMBLY OFA LIFT CYLINDER
ASSEMBLY OFA LIFT CYLINDER
LOAD ROLLERS AND 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 NEW BATTERY
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 MANUAL
OPERATING MANUAL
OPERATOR TRAINING
SERVICE TRAINING COURSES
SERVICE TRAINING MATERIALS
12 ALPHABETICAL INDEX