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Yale High Lift Order Selector 3000: OS030EA Workshop Service Manual
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
CONTACTORSGENERAL
TESTING CONTACTORS
CONTACTORS
CONTACTOR-REMOVE AND INSTALL
CONTACTORDISASSEMBLY AND ASSEMBLY
RELA YS-GENERAL
TES TING RELA Y-CR1
TESTING RELA YCR2
RELAYSREMOVAL AND INSTALLATION
TESTING DIODE BLOCK
REPLACING DIODE BLOCK
TESTING POWER STEERING SOLENOID
REPLACING SOLENOID
ACCELERATOR POTENTIOMETER-REMOVAL AND INSTALLATION
FORWARD AND REVERSE SWITCHESREMOVAL AND INSTALLATION..
LIFT AND LOWER SWITCHESREMOVAL AND INSTALLATION
TROUBLESHOOTING ACCELERATOR SWITCH
HORN SWITCH-REMOVAL AND INSTALLATION
INSTRUMENT PANEL-REMOVAL AND INSTALLATION
KEY SWITCHREMOVAL 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 LIGHTREMOVAL AND INSTALLATION
FOOT SWITCH-REMOVAL AND INSTALLATION
LOOSE CHAIN SWITCHREMOVAL 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 MOTORREMOVAL AND INSTALLATION
BRUSH REPLACEMENT-POWER STEERING MOTOR
POWER STEERING MOTORDISASSEMBLY AND ASSEMBLY
SCHEMATIC
WIRING DIAGRAMDRIVE UNIT COMPARTMENT
WIRING DIAGRAMOPERATORS 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
DESCRIPTIONBRAKE SWITCH
ELECTRIC BRAKE-REMOVAL AND DISASSEMBLY
ELECTRIC BRAKEASSEMBLY 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 MECHANISMASSEMBLY AND INSTALLATION
STEERING CONTA C TOR-REPLACEMENT
DRIVE UNIT POTENTIOMETERREPLACEMENT
ECM-REPLA CEMENT
LOGIC BOARDREPLACEMENT
ECM POWER TRANSISTORREPLACEMENT
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 CHAINSREMOVAL AND INSTALLATION
CHAIN SHEAVEREMOVAL AND INSTALLATION.
MAST ASSEMBLY-REMOVAL
OPERATOR PLATFORMREMOVAL AND INSTALLATION
MAIN CYLINDER-REMOVAL AND INSTALLATION
LOAD ROLLERS AND NEAR PLUGS-REMOVAL AND INSTALLATION
INNER MAST-REMOVAL AND INSTALLATION
MAST ASSEMBLYINSTALLATION
REPAIRS-THREE-STAGE MASTS
FORKS-REMOVAL AND INSTALLATION
HOSESREPLACE
HOIST CHAINREMOVAL AND INSTALLATION
CHAIN SHEAVESREMOVAL AND INSTALLTION
MAST ASSEMBLY REMOVAL
OPERATOR PLATFORMREMOVAL AND INSTALLATION
MAIN CYLINDERREMOVAL AND INSTALLATION
LOAD ROLLERS AND WEAR PLUGSREMOVAL AND INSTALLATION ..
INNER AND INTERMEDIATE MASTREMOVAL AND INSTALLATION.
MAST ASSEMBLY-INSTALLATION
INTRODUCTION-HOIST CYLINDERS
VELOCITY FUSES
FLOW REGULATORS (ALL MODELS)
HOIST CYLINDER (PISTON TYPE) DISASSEMBLY
HOIST CYLINDERASSEMBLY
TROUBLESHOOTING
8 HYDRAULIC SYSTEM
INTRODUCTION
DESCRIPTIONHYDRAULIC SYSTEM
PUMP
RELIEF VALVE
CHECK VALVE
SOLENOID VALVE
FLOW CONTROL VALVE
VELOCITY FUSES
ACCUMULATORS
RELIEF VALVE ADJUSTMENT
HYDRAULIC PUMP-REPAIRS
HYDRAULIC PUMPREMOVAL
SEAL REPLACEMENT
HYDRAULIC PUMPINSTALLATION
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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