PDF Service Repair Manual Yale A474 SS030BF A497 FS030BF D801 OS030EF Lift Truck - 3 MB
This comprehensive service and repair manual covers a range of Yale lift trucks, including the A474, A497, D801, and E826 series (SS030BF, FS030BF, OS030EF, OS030BF models).
It provides technicians with detailed instructions for troubleshooting, maintenance, and major repairs.
With clear diagrams and specifications, this manual is essential for keeping your Yale lift truck fleet operating safely and efficiently.
It's the definitive guide for any service professional.
PDF Viewer
Viewer loads when you scroll here
SHARE THIS MANUAL
Download the PDF Manual
PDF viewer loading area
Text Preview from This Manual
The text below was extracted from the visible preview pages to help you confirm the manual contents before download.
--- Page 1 ---
SS030BF (A474), FS030BF (A497), OS030EF (D801), OS030BF (E826)
SERVICE MANUAL CONTENTS
PART YRM REV
SECTION NUMBER NUMBER 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)
--- Page 3 ---
Guide Wire Physical Installation 2200 YRM 1230
20. Just prior to laying the wire, the slot must be cleared
using an ice pick or similar instrument. Then vac-
uum the slot and surrounding area, to make sure
there are no granules left in the slot. See Figure 13.
Figure 11. Vacuum Slurry Immediately Figure 12. Electric Hand Saw
16. Saw alignment is critical at all times. If the chalk
line is difficult to see, a flashlight can be used. See
Figure 10.
WARNING
If water is used with the electric hand saw, the saw
MUST have an insulated case and care must be
taken to prevent electrical shock.
17. For short distances, to widen the slot for expan-
sion loops, and to deepen the slot when needed,
an electric hand saw can be used. See Figure 12.
Although this can be a dry cut, a water supply for
cooling and lubrication is better. A water type fire
extinguisher filled with water can be used.
18. No special care is given to the slot after cutting. It
can be left overnight without covering it. If left for
long periods, duct tape can be used to keep the slot Figure 13. Vacuum Slot
free of dirt.
21. The wire is installed in the slot directly from the reel.
19. Inspect the entire slot (especially guided sections) A blunt instrument is used to press the wire into
to locate any metal in the slot path that was not the bottom of the slot. The instrument shown in
visible at the surface. Rebar, conduit, or pipe are Figure 14 is a keyhole saw with the blade ground
some examples. If the conduit or pipe are still in smooth. If necessary, use pieces of cork or card-
use, an agreement must be made with the customer board to keep the wire in the bottom of the saw cut.
on the solution to the problem. Remove any metal It is important for correct guidance that the wire is
within 50.8 mm (2 in.) of the slot. Fill the area with kept at the bottom of the saw cut. The cork or card-
epoxy and grind the epoxy flush with the surface. board must be a tight fit in the slot to hold the wire
Cut the slot through the filled area. at the bottom of the slot.
6
--- Page 4 ---
Specifications 2200 YRM 1230
Table 3. General Specifications (Continued)
Item or Area Specification
6. Floor Flatness Lift Heights Floor flatness of Face F65 is recommended. In the direction for truck
to 6096 mm (240 in.) travel, the elevation between any two points separated by 1828.8 mm
(72 in.) will not exceed 4.318 mm (1/6 or 0.17 in.) and will not change
at a rate greater than 3.556 mm (1/7 or 0.14 in.) per 0.3048 m (1 ft) of
travel across the floor. Areas that do not meet the specification must be
corrected (filled or ground) to specification.
Perpendicular to the direction of truck travel, the elevation difference
between any two points separated by 1371.6 mm (54 in.) will not exceed
3.556 mm (1/7 or 0.14 in.) and will not change at a rate greater than
3.556 mm (1/7 or 0.14 in.) per 0.3048 m (1 ft) of travel across the floor.
In any direction, the elevation difference between any two points separated
by 304.8 mm (12 in.) will not exceed 1.778 mm (1/14 or 0.07 in.) and will
not change at a greater rate than 1.778 mm (1/14 or 0.07 in.) per 0.3048 m
(1 ft) of travel across the floor. Areas that do not meet this specification
must be corrected (grounded or filled) to specification.
Sharp discontinuities in truck aisle must be filled or ground so that there is
no jolting of the truck.
7. Floor Flatness Lift Heights Floor flatness of a Face F95 is recommended. In the direction of truck
Above 6096 mm (240 in.) travel, the elevation difference between any two points separated by
1828.8 mm (72 in.) will not exceed 2.794 mm (1/9 or 0.11 in.) and will not
change at a rate greater than 2.032 mm (1/12 or 0.08 in.) per 0.3048 m
(1 ft) of travel across the floor. Areas that do not meet this specification
must be corrected (grounded or filled) to specification.
Perpendicular to the direction of truck travel, the elevation difference
between any two points separated by 1371.6 mm (54 in.) will not exceed
2.54 mm (1/10 or 0.10 in.) and will not change at rate greater than
2.032 mm (1/12 or 0.08 in.) per 0.3048 m (1 ft) of travel across the floor.
In any direction, the elevation difference between any two points separated
by 304.8 mm (12 in.) will not exceed 1.0668 mm (1/24 or 0.042 in.) and
will not change at a rate greater than 1.0668 mm (1/24 or 0.042 in.) per
0.3048 m (1 ft) of travel across the floor. Areas that do not meet this
specification must be corrected (filled or ground) to specification.
Sharp discontinuities in truck aisle must be filled or ground so there is
no jolting of the truck.
8. Floor Magnetic Condition Guidance sensors respond to a magnetic field from the guide wire.
Therefore, all hard topping or any iron or steel must be evenly distributed
within 609.6 mm (24 in.) on both sides of the guide wire. Wire mesh and
rebar must be at least 101.6 mm (4 in.) below the guide wire.
Other magnetic materials, such as pipes, rails, and drains must be at least
152.4 mm (6 in.) below the guide wire.
Other guide wires in the floor with the same or different frequencies must
be at least 762 mm (30 in.) away from the guide wire in the guide path.
16
--- Page 6 ---
Troubleshooting 2200 YRM 1229
1. ELASTIC CAULKING 4. SLOT
2. CONCRETE 5. HOLE
3. GUIDE WIRE
Figure 5. Guide Wire Preparation
5. Put a 101.6 mm (4.0 in.) length of shrinkable tubing 8. Center the shrinkable tubing over each splice and
on each wire. See Figure 6. use a heat gun to shrink the tubing in place.
6. Cut a 355.6 mm (14.0 in.) length of jumper wire and 9. Seal each splice using sealant.
strip 38.1 mm (1.5 in.) of insulation from each end.
Twist the wire strands together. 10. Make a loop in the jumper wire centered over the
hole. See Figure 7.
NOTE: The splice MUST be soldered to provide the re-
quired conductance and corrosion resistance. 11. Put the wire in the groove and push the loop in the
hole so the wire lays flat in the bottom of the slot.
7. Connect the jumper wire and each end of the guide
wire using the "Western Union" splice. Solder each 12. Fill the slot with elastic caulking (silastic silicone).
splice using a 60% tin, 40% lead, non-activated
rosin core solder.
10
--- Page 8 ---
Lift Cylinder Repair 4000 YRM 135
CAUTION
Carefully disassemble and assemble the lift cylin-
ders so that the rods and sliding surfaces are not
damaged.
NOTE: Disassembly of single-stage and two-stage lift
cylinders is the same except the two-stage lift cylinder
has a second piston rod assembly. The disassembly
of the secondary piston rod assembly is similar to the
disassembly of the primary piston rod assembly.
1. Loosen the retainer with a spanner. Disconnect the
retainer from the shell. See Figure 8 and Figure 9.
2. Remove the cap from the inlet and slide the piston
rod assembly from the shell. Use drain pans for the
hydraulic oil.
3. Remove the retainer from the piston rod. Remove
and discard the O-rings, seals, and bearings.
4. Remove the internal check valve.
5. Remove the lowering control valve.
6. Clean all the parts. Check the sliding surfaces for
damage. Repair or replace any damaged parts.
ASSEMBLE
NOTE: Lubricate all internal parts of the lift cylinder with
1. SHEAVE 5. CHAIN ANCHOR hydraulic oil during assembly.
2. SNAP RING 6. WASHER AND NUT
3. CROSSHEAD 7. SHIM
4. CYLINDER GUIDE 8. GUIDE SHOE Use new O-rings, seals, and bearings. Apply lubri-
ASSEMBLY 9. BEARING cant during assembly. Packing lubricant (Part Number
504234269) is available.
Figure 7. Free-Lift Cylinder and Crosshead
Make sure the single-lip seal assemblies are installed
Masts That Have Two Cylinders, Main Lift with the O-ring toward the base of the lift cylinder.
Cylinder and Free-Lift Cylinder The spacers control the maximum stroke of the piston
1. Remove the free-lift cylinder as described in the rod assembly. If a new spacer is necessary, make sure
section above for removing a lift cylinder fastened the same size spacer is installed.
to a crosshead. 1. Install the internal check valve. Make sure the ar-
2. Remove the main lift cylinder as described in the row on the internal check valve is toward the base
section above for removing a lift cylinder fastened of the piston.
to an inner mast.
DISASSEMBLE
WARNING
Use slings and a crane to handle and disassemble
the lift cylinders of most lift trucks. Make sure that
the crane and slings can lift the load.
10
--- Page 9 ---
Lift Cylinders for HI VIS® Masts 4000 YRM 135
2. Remove the protective cap from the inlet and slide
the rod and piston assembly from the shell. Drain
the hydraulic oil into a container.
NOTE: To remove the retainer, the piston rod and piston
assembly must be disassembled if the lift cylinder is the
type shown in Figure 12. Use the following procedure:
a. Put a round bar through the 7.9 mm (0.31 in.)
hole in the piston. Hold the rod in a vise or
clamp so that it does not turn. Use the round
bar and turn the threaded piston from the piston
rod.
b. If an adhesive was used on the threaded rod
and piston, heat the rod to a maximum of 170
to 225°C (300 to 400°F) to loosen the adhesive.
3. Remove the retainer from the piston rod. Remove
and discard the O-rings, seals, and bearings.
4. Remove the internal check valve from the base of
the lift cylinder.
5. Clean all the parts. Check the sliding surfaces for
damage. Repair or replace any damaged parts.
ASSEMBLE
A. INSTALLED B. NOT INSTALLED
NOTE:
1. PISTON AND ROD 4. INLET AND • Lubricate all internal parts of the lift cylinder with hy-
ASSEMBLY OUTLET PORT
2. CHECK VALVE 5. SINGLE-LIP SEAL draulic oil during assembly.
3. O-RING 6. O-RING • Use new O-rings, seals, and bearings. Apply lubri-
7. BACKUP RING cant (hydraulic oil) during assembly. Packing lubri-
cant (Part No. 504234269) is also available.
Figure 13. Internal Check Valve and Single-Lip Seal • Make sure the single-lip seal assemblies are installed
with the O-ring toward the base of the lift cylinder.
DISASSEMBLE (See Figure 13.)
WARNING
CAUTION
Use slings and a crane to handle and disassemble
the lift cylinders of most lift trucks. Make sure that A difficult and important step in assembling lift
the crane and slings can lift the load correctly. cylinders is the correct installation of the seals.
Most lift cylinder maintenance is caused by seal
leaks.
CAUTION
Carefully disassemble and assemble the lift cylin- 1. Install the internal check valve, if installed. Make
ders so that the piston rods and sliding surfaces sure the arrow on the internal check valve is toward
are not damaged. the base of the piston.
NOTE: Disassembly of the main lift cylinders and the 2. Install the wear ring, single lip seal, and backup
free-lift cylinder is similar. All of the lift cylinders are ring onto the piston assembly. If a spacer sleeve is
disassembled from the rod end of the cylinder shell. used, install it. Use shim material and a clamp as
a guide to move the single-lip seal over the threads
1. Loosen the retainer with a spanner. Disconnect the of the shell.
retainer from the shell.
20
--- Page 10 ---
SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Yale® dealer.
Service Manuals provide general guidelines for maintenance and service and are intended for use by
trained and experienced technicians. Failure to properly maintain equipment or to follow instructions con-
tained in the Service Manual could result in damage to the products, personal injury, property damage or
death.
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the
load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the
weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift
trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK
ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use YALE APPROVED parts when making repairs. Replacement parts must meet or exceed the
specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to re-
move parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit
needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable.
Be sure to follow the necessary safety precautions when handling these fuels and when working on these
fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area.
Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this man-
ual:
WARNING
Indicates a hazardous situation which, if not avoided, could result in death
or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
--- Page 11 ---
General 8000 YRM 0231
FASTENER TORQUE TABLES
Table 5. Torque Values for Metric Fasteners*
Property Class 5.81 Grade 8.82 Grade 10.93
Size and Pitch
N•m lbf ft N•m lbf ft N•m lbf ft
M3 × 0.5 M3.5 × 0.6 M4 × 0.62 0.97 0.5 0.7 1.1 0.99 1.55 0.7 1.1 2.1 1.34 2.11 1.0 1.6 2.3
0.7 M5 × 0.8 M6 × 1 1.44 2.91 2.1 3.6 2.30 4.65 3.6 6 3.13 6.33 4.7 8
4.94 7.90 10.8
M8 × 1.25 M8 × 1 M10 × 12.0 12.8 9 9 18 19 19.2 20.5 14 15 28 30 26.1 27.9 52 19 21 38 41
1.5 M10 × 1.25 23.8 25.1 38.0 40.1 55
M12 × 1.75 M12 × 1.25 41.4 45.3 66 31 33 49 53 66 72 105 49 53 77 85 90 98 145 66 72 105
M14 × 2 M14 × 1.5 72 115 155 115
M16 × 2 M16 × 1.5 M20 × 105 110 200 77 81 150 165 175 320 122 130 235 225 240 435 165 175 320
2.5 M20 × 1.5 225 165 355 260 485 360
M24 × 3 M24 × 2 M27 × 3 345 375 505 255 275 370 555 605 810 410 445 600 755 820 560 605 810
M27 × 2 550 405 875 645 1,100 1,190 880
M30 × 3.5 M30 × 3 M30 × 690 715 765 510 530 565 1,100 1,140 810 840 900 1,500 1,550 1,100 1,140
2 M33 × 3.5 M33 × 2 940 1,030 695 760 1,220 1,500 1,100 1,210 1,660 2,040 1,230 1,510
1,640 2,240 1,660
M36 × 4 M36 × 3 M39 × 4 1,200 1,280 885 945 1,930 2,040 1,430 1,510 2,620 2,780 1,940 2,050
M39 × 3 1,560 1,640 1,150 1,210 2,490 2,630 1,840 1,940 3,390 3,570 2,500 2,640
M42 × 4.5 M42 × 3 M45 × 1,930 2,070 1,430 1,530 3,080 3,320 2,280 2,450 4,200 4,510 3,100 3,330
4.5 M45 × 3 M48 × 5 M48 2,410 2,580 1,780 1,910 3,850 4,120 2,840 3,040 5,240 5,610 3,870 4,140
×3 2,900 3,160 2,140 2,330 4,630 5,040 3,420 3,720 6,300 6,860 4,650 5,060
* Unless otherwise specified 1 Approximately equal to Grade 2 2 Approximately equal to Grade 5 3 Approximately equal to
Grade 8
8
--- Page 13 ---
Hydraulic Gear Pump Repair 1900 YRM 97
NOTE: THERE CAN BE A VARIATION OF INTERNAL PARTS ON DIFFERENT MODELS OF LIFT TRUCKS.
1. REAR COVER 9. FRONT COVER
2. SEAL GLAND 10. STUD
3. SEAL RETAINER 11. WASHER
4. REAR WEAR PLATE 12. NUT
5. DRIVEN GEAR 13. SEAL
6. DRIVE GEAR 14. SNAP RING
7. GEAR HOUSING 15. SEAL
8. FRONT WEAR PLATE 16. PIN
Figure 7. Hydraulic Gear Pump Single-Stage
NOTE: Some pump bodies will show gear marks where is in the oil. Small holes in the outlet side of the
the gears rotate because of the small clearances be- gear chamber indicate that cavitation has occurred.
tween the parts. These gear marks do not indicate a Make sure inlet hose, fittings, and tank have no re-
worn or damaged pump unless the pump will not supply strictions. Cavitation can also occur when the en-
the volume and pressure shown in the specifications. gine speed is too high.
3. Inspect gear housing for wear or grooves. Most If the surfaces of the gear chamber or gear teeth
wear occurs on the inlet side of the gear chamber. have blue marks, the pump was too hot. Heat dam-
Put a straight edge across the inlet side of the gear age in the pump can be caused by hot oil or lack of
chamber. If a 0.13 mm (0.005 in.) thickness gauge oil. Check front seal surface to see if air was en-
fits between the straight edge and the housing, the tering the pump through the front seal. Make sure
gear housing must be replaced. If the gear housing the oil is the correct viscosity. The wrong viscosity
is worn, inspect bearings for wear. If the system oil can increase leakage within the pump. Leakage
pressure is too high, the gear housings will wear inside the pump increases the oil temperature.
quickly. Grooves in the gear chamber indicate dirt
6
--- Page 14 ---
Troubleshooting 1900 YRM 97
PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION
Air in the hydraulic system. Low oil level in hydraulic tank. Fill hydraulic oil tank to correct level.
Leak in inlet hose. Replace inlet hose.
Loose inlet fitting. Tighten inlet fitting.
Breather on hydraulic tank has a re- Replace hydraulic tank breather.
striction.
Supply hose is twisted or has a restric- Remove twist or remove restriction.
tion.
Screen in hydraulic tank has a restric- Clean hydraulic tank screen.
tion.
Pump seal is damaged. Replace pump seal.
Check valve in pump is damaged. Replace check valve.
Pump housing capscrews are loose. Tighten pump housing screws to cor-
rect torque.
Worn or damaged hydraulic pump. Repair or replace hydraulic pump.
16
--- Page 15 ---
Brush and Commutator Inspection 620 YRM 294
Table 1. Normal Commutator Surfaces (Continued)
A condition called slot bar marking is also normal A very dark surface is also a normal and an acceptable
if the commutator surface is smooth. The variable condition if the commutator surface is smooth.
color occurs in a pattern according to the number of
conductors per slot.
STEERING PUMP MOTOR 3. Install brush covers and screws. Install floor plate
or close hood and connect battery connector.
NOTE: Some electrical trucks use a steering pump mo-
tor. Refer to your truck model’s service manual for in- NORMAL COMMUTATOR SURFACE
structions on removal and installation of steering pump
motors. A commutator that has been in service will have a
smooth and polished surface with a darker brown color
1. Disconnect battery connector. Remove floor plate where it rotates under the brushes. See Table 1. A
from lift truck for access to steering pump motor. variation of color on the commutator surface between
Open hood for access to motor. Remove screws light brown and darker brown is normal. This surface
that hold two brush cover plates to motor housing. condition is the lubrication between the commutator