Yale OS030EC - User Manual

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SS030BF (A474), FS030BF (A497), OS030EF (D801), OS030BF (E826)

SERVICE MANUAL CONTENTS

SECTION

PART

NUMBER

YRM

NUMBER

REV

DATE

FRAME............................................................................................................................ 524163979 0100 YRM 0760 01/12

DC MOTOR MAINTENANCE.......................................................................................... 524158039 0620 YRM 0294 03/08

AC MOTOR REPAIR...................................................................................................... 550032942 0620 YRM 1461 01/12

A/C MOTOR REPAIR S/N A474N03000L=> S/N A497N030000L=> S/N

D801N02161L=> S/N E826N01917L=>..................................................................... 550073166 0620 YRM 1621 02/14

MASTER DRIVE UNIT.................................................................................................... 550032941 0630 YRM 1460 01/12

MASTER DRIVE UNIT S/N D801N03000L=> S/N A474N03000L=> S/N

A497N030000L=> S/N E826N03000L=>................................................................... 550073167 0630 YRM 1609 06/14

STEERING SYSTEM...................................................................................................... 550032943 1600 YRM 1462 01/12

BRAKE SYSTEM............................................................................................................ 550032944 1800 YRM 1463 01/12

HYDRAULIC GEAR PUMP............................................................................................. 524153907 1900 YRM 0097 05/12

HYDRAULIC SYSTEM [D801 (OS030EF)]..................................................................... 550032945 1900 YRM 1464 08/14

HYDRAULIC SYSTEM (LARGE).................................................................................... 550032946 1900 YRM 1465 05/12

WIRE DRIVER MANUAL................................................................................................ 520371765 2200 YRM 1229 01/12

GUIDE WIRE INSTALLATION........................................................................................ 520371764 2200 YRM 1230 01/12

AC MOTOR CONTROLLER........................................................................................... 550032947 2200 YRM 1466 02/14

ELECTRICAL SYSTEM [D801 (OS030EF)]................................................................... 550032948 2200 YRM 1467 08/14

ELECTRICAL SYSTEM (LARGE).................................................................................. 550032949 2200 YRM 1468 01/12

USER INTERFACE SUPERVISOR FUNCTIONS =>S/N A474N02999L =>S/N

A479N02999L =>S/N D801N02999L =>S/N E826N02999L...................................... 550032950 2200 YRM 1469 12/13

USER INTERFACE SERVICE-LEVEL FUNCTIONS =>S/N A474N02999L =>S/N

A479N02999L =>S/N D801N02999L =>S/N E826N02999L...................................... 550032951 2200 YRM 1470 12/13

WIRE GUIDANCE........................................................................................................... 550032952 2200 YRM 1471 05/13

USER INTERFACE SUPERVISOR FUNCTIONS S/N D801N03000L=> S/N

A474N03000L=> S/N A497N030000L=> S/N E826N03000L=>............................... 550089217 2200 YRM 1650 12/13

USER INTERFACE SERVICE TECHNICIAN S/N A474N03000L=> S/N

A497N030000L=> S/N D801N03000L=> S/N E826N03000L=>............................... 550089220 2200 YRM 1651 12/13

INDUSTRIAL BATTERY................................................................................................. 524158040 2240 YRM 0001 09/14

LIFT CYLINDERS........................................................................................................... 524150794 4000 YRM 0135 03/11

MAST-DESCRIPTION..................................................................................................... 524164052 4000 YRM 0763 01/12

MAST-REPAIR................................................................................................................ 524164053 4000 YRM 0764 01/12

METRIC AND INCH (SAE) FASTENERS....................................................................... 524150797 8000 YRM 0231 10/13

PERIODIC MAINTENANCE............................................................................................ 550032953 8000 YRM 1472 02/14

DIAGRAMS..................................................................................................................... 550032954 8000 YRM 1473 11/12

CAPACITIES AND SPECIFICATIONS........................................................................... 550032955 8000 YRM 1474 10/13

CONTROLLER DIAGNOSTICS...................................................................................... 550089223 9000 YRM 1648 10/14

PART NO. 550032940 (10/14)

Main Page

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Summary

FRAME

General

Provides a general description of the frame parts, including weldments, doors, and covers.

Description

Details the frame's mounts for various systems like upright, steering, and electrical components.

Frame Repair

Remove and Disassemble

Procedure for removing frame components, with crucial safety warnings for material decomposition.

Covers, Panels, and Plates

Instructions for removing protective covers, panels, and plates to access internal parts.

Caster and Caster Wheels

Description of the caster unit, its function, and its connection to the forklift frame.

Caster, Replace

Step-by-step instructions for replacing the entire caster assembly on the lift truck.

Caster Wheels, Replace

Procedure for replacing individual caster wheels, emphasizing replacing them as a set.

BRAKE SYSTEM

Safety Precautions Maintenance and Repair

General safety guidelines and precautions applicable to maintenance and repair operations.

Summary

FRAME

General

Provides a general description of the frame parts, including weldments, doors, and covers.

Description

Details the frame's mounts for various systems like upright, steering, and electrical components.

Frame Repair

Remove and Disassemble

Procedure for removing frame components, with crucial safety warnings for material decomposition.

Covers, Panels, and Plates

Instructions for removing protective covers, panels, and plates to access internal parts.

Caster and Caster Wheels

Description of the caster unit, its function, and its connection to the forklift frame.

Caster, Replace

Step-by-step instructions for replacing the entire caster assembly on the lift truck.

Caster Wheels, Replace

Procedure for replacing individual caster wheels, emphasizing replacing them as a set.

BRAKE SYSTEM

Safety Precautions Maintenance and Repair

General safety guidelines and precautions applicable to maintenance and repair operations.

Overview

This document outlines the service and maintenance procedures for a range of Yale Order Selector lift trucks, specifically models SS030BF [A474], FS030BF [A497], OS030EC [C801], OS030EF [D801], OS/SS030BE [D826], and OS030BF [E826]. The manual is structured to provide comprehensive guidance on various components and systems of these industrial vehicles, ensuring their safe and efficient operation and upkeep.

The primary function of these devices is to serve as order selectors, designed for lifting and transporting goods within a warehouse or industrial setting. They enable operators to pick items from various heights, facilitating efficient inventory management and order fulfillment. The design emphasizes stability and maneuverability, crucial for navigating confined spaces and handling diverse loads.

Key usage features are integrated throughout the design. The frame, a fundamental component, provides the structural integrity for the entire lift truck. It incorporates mounts for the upright assembly, steering system, electrical system, and hydraulic system, as well as doors, access panels, and covers. The outer channel of the upright and the base arms are integral parts of the frame weldment, contributing to the overall stability and load-bearing capacity. The steering system allows for precise control, essential for navigating aisles and positioning the truck accurately. The brake system ensures safe stopping and control, a critical safety feature in any industrial vehicle. Hydraulic systems, including the gear pump, facilitate lifting and lowering operations, enabling the operator to access goods at different elevations. The electrical system, with its dedicated controller, manages various functions and ensures reliable operation. Wire guidance features are also available, enhancing precision and efficiency in guided aisle applications.

Maintenance features are extensively detailed to ensure the longevity and safe operation of the lift trucks. The manual provides specific instructions for maintaining the DC motor, a critical component for propulsion. Procedures for AC motor repair are also outlined, covering models with specific serial number ranges (S/N A474N03000L=> S/N A497N030000L=> S/N D801N02161L=> S/N E826N01917L=>). The master drive unit, another essential part of the propulsion system, has dedicated maintenance guidelines, including specific instructions for units within certain serial number ranges (S/N D801N03000L=> S/N A474N03000L=> S/N A497N030000L=> S/N E826N03000L=>).

The manual also covers the maintenance of various structural and operational components. Frame repair instructions address general descriptions, removal and disassembly of covers, panels, and plates, as well as the caster and caster wheels. The caster, which provides support for the front of the lift truck, is an articulated axle design, allowing both wheels to maintain equal weight distribution for better operation and wear. Instructions are provided for replacing the entire caster assembly or individual caster wheels, emphasizing the importance of replacing wheels as a set to prevent uneven wear.

User interface functions are detailed, with specific instructions for supervisor and service-level functions, categorized by serial number ranges. This ensures that operators and technicians can effectively interact with and diagnose issues within the system. Wire guidance systems also have dedicated maintenance sections.

Beyond mechanical and electrical systems, the manual addresses other crucial aspects of maintenance. Industrial battery maintenance is covered, ensuring proper care and longevity of the power source. Lift cylinders and mast components, including description and repair procedures, are detailed to maintain lifting capabilities. The manual also includes information on metric and inch (SAE) fasteners, ensuring correct hardware usage during repairs. Periodic maintenance schedules are provided, outlining routine checks and services necessary for optimal performance and safety. Diagrams are included to aid in visual identification of components and systems. Capacities and specifications are listed to provide essential operational data. Finally, controller diagnostics are covered, enabling technicians to troubleshoot and resolve issues related to the lift truck's control systems.

Safety precautions are paramount throughout the manual. General safety guidelines emphasize the importance of using proper lifting equipment, wearing safety glasses, disconnecting the battery connector before maintenance, and using correct blocks to prevent movement. The use of YALE APPROVED parts is mandated for repairs to ensure compatibility and performance. Fastening a "DO NOT OPERATE" tag during repairs is also a critical safety measure. Warnings and cautions are highlighted, particularly regarding flammable materials like gasoline, LPG, CNG, and diesel fuel, and the flammable gases generated by batteries during charging. Specific warnings are also given for handling polyurethane paint during welding or burning, due to the release of isocyanates, requiring adequate ventilation and respiratory protection.

The manual also provides instructions for painting and label replacement. Painting guidelines emphasize surface preparation, rust removal, priming, and the use of correct Yale paint. Label replacement instructions stress the importance of immediately replacing damaged warning or instruction labels, ensuring that critical safety and operational information remains visible and legible. This comprehensive approach to maintenance, coupled with a strong emphasis on safety, ensures that the Yale Order Selector lift trucks can be operated and maintained effectively and safely throughout their service life.