Page 1

SS030BF (A474), FS030BF (A497), OS030EF (D801), OS030BF (E826) SERVICE MANUAL CONTENTS SECTION FRAME............................................................................................................................ DC MOTOR MAINTENANCE.......................................................................................... AC MOTOR REPAIR...................................................................................................... A/C MOTOR REPAIR S/N A474N03000L=> S/N A497N030000L=> S/N D801N02161L=> S/N E826N01917L=>..................................................................... MASTER DRIVE UNIT.................................................................................................... MASTER DRIVE UNIT S/N D801N03000L=> S/N A474N03000L=> S/N A497N030000L=> S/N E826N03000L=>................................................................... STEERING SYSTEM...................................................................................................... BRAKE SYSTEM............................................................................................................ HYDRAULIC GEAR PUMP............................................................................................. HYDRAULIC SYSTEM [D801 (OS030EF)]..................................................................... HYDRAULIC SYSTEM (LARGE).................................................................................... WIRE DRIVER MANUAL................................................................................................ GUIDE WIRE INSTALLATION........................................................................................ AC MOTOR CONTROLLER........................................................................................... ELECTRICAL SYSTEM [D801 (OS030EF)]................................................................... ELECTRICAL SYSTEM (LARGE).................................................................................. USER INTERFACE SUPERVISOR FUNCTIONS =>S/N A474N02999L =>S/N A479N02999L =>S/N D801N02999L =>S/N E826N02999L...................................... USER INTERFACE SERVICE-LEVEL FUNCTIONS =>S/N A474N02999L =>S/N A479N02999L =>S/N D801N02999L =>S/N E826N02999L...................................... WIRE GUIDANCE........................................................................................................... USER INTERFACE SUPERVISOR FUNCTIONS S/N D801N03000L=> S/N A474N03000L=> S/N A497N030000L=> S/N E826N03000L=>............................... USER INTERFACE SERVICE TECHNICIAN S/N A474N03000L=> S/N A497N030000L=> S/N D801N03000L=> S/N E826N03000L=>............................... INDUSTRIAL BATTERY................................................................................................. LIFT CYLINDERS........................................................................................................... MAST-DESCRIPTION..................................................................................................... MAST-REPAIR................................................................................................................ METRIC AND INCH (SAE) FASTENERS....................................................................... PERIODIC MAINTENANCE............................................................................................ DIAGRAMS..................................................................................................................... CAPACITIES AND SPECIFICATIONS........................................................................... CONTROLLER DIAGNOSTICS...................................................................................... PART NO. 550032940 (10/14)

PART NUMBER

YRM NUMBER

REV DATE

524163979 524158039 550032942

0100 YRM 0760 0620 YRM 0294 0620 YRM 1461

01/12 03/08 01/12

550073166 550032941

0620 YRM 1621 0630 YRM 1460

02/14 01/12

550073167 550032943 550032944 524153907 550032945 550032946 520371765 520371764 550032947 550032948 550032949

0630 YRM 1609 1600 YRM 1462 1800 YRM 1463 1900 YRM 0097 1900 YRM 1464 1900 YRM 1465 2200 YRM 1229 2200 YRM 1230 2200 YRM 1466 2200 YRM 1467 2200 YRM 1468

06/14 01/12 01/12 05/12 08/14 05/12 01/12 01/12 02/14 08/14 01/12

550032950

2200 YRM 1469

12/13

550032951 550032952

2200 YRM 1470 2200 YRM 1471

12/13 05/13

550089217

2200 YRM 1650

12/13

550089220 524158040 524150794 524164052 524164053 524150797 550032953 550032954 550032955 550089223

2200 YRM 1651 2240 YRM 0001 4000 YRM 0135 4000 YRM 0763 4000 YRM 0764 8000 YRM 0231 8000 YRM 1472 8000 YRM 1473 8000 YRM 1474 9000 YRM 1648

12/13 09/14 03/11 01/12 01/12 10/13 02/14 11/12 10/13 10/14


Maintenance

FRAME ORDER SELECTOR SS030BF [A474]; FS030BF [A497]; OS030EC [C801]; OS030EF [D801]; OS/SS030BE [D826]; OS030BF [E826]

PART NO. 524163979

100 YRM 760


SAFETY PRECAUTIONS MAINTENANCE AND REPAIR • 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 remove 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 manual:

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 background. The CAUTION symbol and word are on yellow background.


Frame

Table of Contents

TABLE OF CONTENTS General................................................................................................................................................................ Description .......................................................................................................................................................... Frame Repair....................................................................................................................................................... Remove and Disassemble .............................................................................................................................. Covers, Panels, and Plates ............................................................................................................................. Caster and Caster Wheels .............................................................................................................................. Description.................................................................................................................................................. Caster, Replace .......................................................................................................................................... Caster Wheels, Replace ............................................................................................................................. Painting Instructions ............................................................................................................................................ Label Replacement..............................................................................................................................................

1 1 2 2 2 2 2 3 3 4 4

This section is for the following models: SS030BF [A474]; FS030BF [A497]; OS030EC [C801]; OS030EF [D801]; OS/SS030BE [D826]; OS030BF [E826]

©2012 Yale Materials Handling Corp.

i


100 YRM 760

Description

General This manual has the description for the parts of the frame. Parts include the frame weldment, doors, battery rollers, covers, casters, caster wheels and battery

panels. The outer channel of the upright is part of the lift truck frame. The base arms are part of the weldment for the outer channel of the upright.

Description The frame has mounts for the upright assembly, steering system, electrical system, hydraulic system, doors, access panels, and covers. See Figure 1.

Figure 1. Frame (FS030BF, OS030BE, OS030BF, OS030EC, and OS030EF)

1


Frame Repair

100 YRM 760

Legend for Figure 1 1. 2. 3. 4. 5. 6. 7. 8.

STUD SPRING CUPPED WASHER RETAINER NUT COVER HINGE PIN RH DOOR

9. 10. 11. 12. 13.

THUMB SCREW LH DOOR BATTERY ROLLER BATTERY PANEL BASE ARM WELDMENT (OS030BE, OS030BF, OS030EC, AND OS030EF SHOWN) 14. FRAME WELDMENT

Frame Repair REMOVE AND DISASSEMBLE WARNING Forklift truck frames and components may have polyurethane paint. Welding, burning, or other heat sufficient to cause thermal decomposition of the paint may release isocyanates. These chemicals are allergic sensitizers to the skin and respiratory tract; overexposure may occur without odor warning. Should work be performed, utilize good industrial hygiene practices, including removal of all paint (prime and finish coats) to the metal around the area to be welded, local ventilation, and/or supplied-air respiratory protection.

The drive wheel of the master drive unit is the other support for this end of the lift truck. The axle of the caster is an articulated axle. The articulated axle permits both wheels of the caster to always have equal weight. This allows for better operation and wear. The caster is fastened to the frame weldment by four capscrews and lockwashers. The complete caster can be replaced as a unit, or the wheels can be replaced. Always replace the wheels as a set for better caster operation and wheel wear. A single new wheel of the set will wear rapidly.

There is very little repair required on the frame. See Figure 1. Most repairs can be done by removing the necessary system parts. Refer to the section for the system that must be removed. To separate the frame weldment from the upright weldment, see the section Mast, Repair 4000 YRM 764. To replace the load wheels in the load arms, see the section Periodic Maintenance 8000 YRM 924 or Periodic Maintenance 8000 YRM 1472.

COVERS, PANELS, AND PLATES The special plastic covers that protect the parts can be removed by removing the screws that fasten them. See Figure 1. There is one cover over the main frame weldment. Two doors provide access to the electrical and hydraulic compartments. The panels at each end of the battery compartment can be removed by lifting them straight up and out of the slots in the frame.

CASTER AND CASTER WHEELS Description The caster is one support for the front of the lift truck and is under the hydraulic compartment. See Figure 2.

2

1. 2. 3. 4.

FRAME WELDMENT CASTER ASSEMBLY LOCKWASHER CAPSCREW

Figure 2. Caster (SS030BE and SS030BF)


100 YRM 760

Frame Repair

Caster, Replace 1. Put the rear of the lift truck on blocks. See How to Put Lift Truck on Blocks in the section Periodic Maintenance 8000 YRM 924 or Periodic Maintenance 8000 YRM 1472. 2. Remove the four capscrews and lockwashers that fasten the plate of the caster to the frame weldment. Remove the caster. See Figure 2. 3. Install the replacement caster using the capscrews and lockwashers. Tighten the capscrews to 68 N•m (50 lbf ft).

Caster Wheels, Replace NOTE: Always replace the wheels as a set. Replacing only one wheel causes more wear on the new wheel. The caster also will not operate correctly, causing more wear or caster damage.

1. 2. 3. 4.

CASTER WHEEL AXLE GUARD WASHERS BEARING

1. Put the rear of the lift truck on blocks. See How to Put Lift Truck on Blocks in the section Periodic Maintenance 8000 YRM 924 or Periodic Maintenance 8000 YRM 1472. 2. Remove the cotter pin, axle nut, lockwasher, and guard washers at each caster wheel. Remove each caster wheel. See Figure 3. 3. Completely fill new bearings with the grease shown in the Maintenance Schedule of the section Periodic Maintenance 8000 YRM 924 or Periodic Maintenance 8000 YRM 1472. Install the bearings in the replacement wheels. 4. Install the guard washers on both sides of the bearing on each wheel. Install the wheel, lockwasher, and nut. Rotate each wheel as you tighten the nut. Tighten each nut to remove all clearance. There will be a resistance to rotation of the wheel. Install a new cotter pin.

5. LOCKWASHER 6. NUT 7. COTTER PIN

Figure 3. Caster Wheels

3


Label Replacement

100 YRM 760

Painting Instructions solvent for painted surfaces. Do not use solvent on new paint.

WARNING To avoid personal injury, always use solvents and paints in an area with ventilation. Do not use solvents or paints near heat, fire, or electrical equipment that can make sparks. Follow the manufacturer’s instructions and cautions.

CAUTION

2. Use sandpaper to remove the top surface of the paint and rust from the metal. All metal surfaces where the paint is completely removed must be primed. Apply a primer and allow to dry before applying the coat of paint. 3. Protect all surfaces that will not be painted.

Do not paint the pads, plastic covers, knobs, cables, decals, information plates, or controls. 1. Remove all dirt, soil, and grease from the surface to be painted. Clean the area to be painted with a

4. Paint the surfaces. Use the correct Yale paint. Follow the directions on the container. Contact your Yale dealer for the correct arrangement of the paint colors.

Label Replacement WARNING To avoid personal injury or property damage, labels that have warnings or instructions that are damaged must be replaced immediately. If the labels or information plates are missing or have damage, they must be replaced. See Figure 4 or Figure 5 for label and plate loctaions. NOTE: The nameplate is installed using rivets. The old rivets must be removed before installing a new nameplate or to change the nameplate information.

4

1. Make sure the surface is dry and has no oil or grease. Do not use solvent on new paint. Clean the surface of old paint using a cleaning solvent. 2. Remove the paper from the back of the label. Do not touch the adhesive surface. 3. Carefully hold the label in the correct position above the surface. Install the label in the correct position on the surface. Make sure all air is removed from under the label and the corners and edges are tight.


100 YRM 760

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Label Replacement

YALE NAMEPLATE YALE LABEL YALE LABEL ACCENT STRIPE LABEL MANUAL LOWERING LABEL MANUAL LOWERING LABEL OPERATOR WARNING LABEL OVERHEAD GUARD WARNING PLATE IGNITION SWITCH LABEL FORK WARNING LABEL BASE

12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.

COVER RIVET MAST WARNING LABEL CAPACITY NAMEPLATE COVER RIVET MULTIFUNCTION CONTROL LABEL PATENTS AND TRADEMARKS LABEL UL PLATE OPERATING MANUAL EE LABEL

Figure 4. Decal and Plate Location (OS030EC and OS/SS/FS030BE)

5


Label Replacement

100 YRM 760

Figure 5. Decal and Plate Location (FS030BF, OS030BF, OS030EF, and SS030BF)

6


100 YRM 760

Label Replacement

Legend for Figure 5 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

NAMEPLATE YALE DECAL YALE DECAL IMPACT RATING PLATE KEY SWITCH LABEL INFO CASE BASE INFO CASE COVER RIVET CAPACITY NAMEPLATE NAME PLATE COVER RIVET MULTI FUNCTION CONTROL LABEL PATENTS AND TRADEMARKS LABEL GREENVILLE MANUFACTURING LABEL MANUAL LOWERING VALVE LABEL

16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30.

MANUAL LOWERING VALVE LOCATION LABEL INSTRUMENT PANEL LABEL ACCENT STRIPE LABEL COLD STORAGE LABEL SUBZERO LABEL U.L. INSPECTION LABEL EE IDENTIFICATION MARKER BATTERY NOTICE LABEL MAST WARNING LABEL PINCH POINT LABEL MAST WARNING LABEL OPERATOR WARNING LABEL WARNING LABEL NAMEPLATE TAG LABEL MAINTENANCE FREE INSTRUCTIONS LABEL

7


NOTES ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

8


Maintenance

BRAKE SYSTEM SS030BF [A474]; FS030BF [A497]; OS030EF [D801]; OS030BF [E826]

PART NO. 550032944

1800 YRM 1463


SAFETY PRECAUTIONS MAINTENANCE AND REPAIR • 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 remove 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 manual:

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 background. The CAUTION symbol and word are on yellow background.


Brake System

Table of Contents

TABLE OF CONTENTS General................................................................................................................................................................ Special Precautions............................................................................................................................................. Description .......................................................................................................................................................... Repair .................................................................................................................................................................. Air Gap ............................................................................................................................................................ Remove ........................................................................................................................................................... Install............................................................................................................................................................... Operational Check............................................................................................................................................... Troubleshooting ...................................................................................................................................................

1 2 3 4 4 5 6 6 7

This section is for the following models: SS030BF [A474]; FS030BF [A497]; OS030EF [D801]; OS030BF [E826]

©2012 Yale Materials Handling Corp.

i


1800 YRM 1463

General

General This section contains the description and replacement procedures for the spring applied, electrically-released parking brake. Some parts associated with the brake system are not covered in this section because they are more closely associated with other systems. See the section Electrical System 2200 YRM 1467 or Electrical System 2200 YRM 1468 for the brake foot switch.

WARNING DO NOT operate a lift truck that needs repairs. If a repair is necessary, attach a DO NOT OPERATE tag to the control handle and disconnect the battery.

WARNING Before performing repairs or adjustments on the brake system, blocks must be placed under each side of the frame to raise the drive tire off the ground. The blocks must prevent the lift truck from falling and causing personal injury or property damage. See Periodic Maintenance 8000 YRM 1472, How to Raise the Drive Tire. Throughout this section, forward will refer to an operator standing in the truck facing the steer tire with the forks trailing. Left and right will be determined by the point of view of an operator situated in the operator compartment and facing the steer tire. See Figure 1.

A. LEFT SIDE B. RIGHT SIDE C. FORWARD TRAVEL

Figure 1. Truck Orientation

1


Special Precautions

1800 YRM 1463

Special Precautions WARNING The capacitor in the transistor controller can hold an electrical charge after the battery is disconnected. To prevent electrical shock and personal injury, discharge the capacitor before inspecting or repairing any component. Wear safety glasses. Make certain the battery has been disconnected. Discharge the capacitors in the controller by connecting a 200-ohm, 2-watt resistor across the controller’s B+ and B terminals with insulated jumper wires. DO NOT use a screwdriver to discharge the traction motor controller.

4. Discharge the capacitors in the controllers by connecting a 200-ohm, 2-watt resistor across the controller’s B+ and B terminals. See Figure 2. DO NOT short across the motor controller terminals with a screwdriver or jumper wire. 5. Remove the 200-ohm, 2-watt resistor. Reinstall the electrical compartment cover when repairs are complete.

To avoid personal injury and prevent electrical shock, perform the following steps before performing any troubleshooting or adjustments, and before connecting or disconnecting a handset or computer.

CAUTION To avoid controller damage, always disconnect the battery. Discharge the capacitor and never put power to the controller with any power wire disconnected. Never short any controller terminal or motor terminal to battery. Make sure to use proper procedure when servicing the controller. 1. Move the lift truck to a safe, level area and completely lower the mast. Turn the key switch to the OFF position and attach a DO NOT OPERATE tag to the control handle. Block the drive wheel to prevent unexpected movement. See How to Put a Lift Truck on Blocks in Periodic Maintenance 8000 YRM 1472. 2. Disconnect the battery. 3. Remove the electrical compartment cover to access the controller.

2

1. 2. 3. 4.

NEGATIVE CONNECTION POSITIVE CONNECTION INSULATED JUMPER WIRES 200-OHM, 2-WATT RESISTOR

Figure 2. Discharging the Controller


1800 YRM 1463

Description

Description The electric brake is located in the drive unit compartment mounted to the top of the traction motor. It consists of a spring-applied, electrically-released brake mounted directly to the drive motor. See Figure 3.

The master controller breaks the power supply to the brake coil, to engage the electric brake when the truck is stopped. Pressing the emergency disconnect switch will engage the electric brake immediately in any mode of operation. The electric brake may be manually disengaged for towing by inserting two standard 1/4-20 Ă— 1-1/4 in. capscrews into the two service ports in the top of the brake assembly. See Figure 4.

1. TRACTION MOTOR 2. BRAKE ASSEMBLY

Figure 3. Brake Location The electric brake is controlled by the master controller. After receiving input signals from the floor switches and a traction input from the multifunction control handle, the master controller will complete the circuit to provide power to the brake coil, disengaging the brake.

1. 2. 3. 4.

SERVICE CAPSCREWS SERVICE PORTS BRAKE ASSEMBLY ASSEMBLY HOLES

Figure 4. Manual Disengage

3


Repair

1800 YRM 1463

Repair AIR GAP

or releasing before the other due to internal damage or tampering. Replace the entire brake assembly. Refer to the Remove section in this manual.

CAUTION The brake is not adjustable. Check the air gap to determine if replacement is necessary. NOTE: The air gap is very thin and may not be checked visually. Dimensions are not to scale and are for location references only. 1. Check the three outer socket head screws for appropriate torque to secure the brake to the motor. 2. Check for the correct air gap by measuring the distance between the bottom of the stator and the top of the pressure plate with the brake engaged (disconnected) using feeler gauges. See Figure 5. See Table 1 for brake specifications. 3. The air gap should be checked for minimum and maximum clearance at the six locations shown in Figure 6. 4. If the air gap allows the maximum feeler gauge to enter any of the six locations, replace the entire brake assembly. Refer to the Remove section in this manual. 5. If the air gap is too tight for a minimum feeler gauge to enter any of the six locations, the air gap has been altered by internal damage or tampering. Replace the entire brake assembly. Refer to the Remove section in this manual. 1. 2. 3. 4.

NOTE: During brake operation, the brake should engage and disengage with a solid, single-click noise. 6. Listen to verify the brake engages and disengages in one smooth operation. A double-clicking noise indicates that one side of the brake disc is applying

STATOR AIR GAP PRESSURE PLATE FEELER GAUGE

Figure 5. Air Gap

Table 1. Specifications Truck Model FS/OS/SS030BF/ OS030EF

4

Air Gap Min

Max

0.20 mm (0.008 in.)

0.40 mm (0.016 in.)

Mounting Capscrews Torque 10.8 N•m (8 lbf ft)

Minimum Friction Disk Thickness 8.50 mm (0.33 in.)


1800 YRM 1463

Repair 7. Lift the brake assembly up off the hub and the motor housing. See Figure 7

Figure 6. Check Locations

REMOVE The following procedures detail the removal and installation for the electric brake. The brake assembly is nonadjustable and contains no serviceable parts. If the brake fails to function, it must be replaced as a complete assembly. Check the electric brake before each use for proper operation. Refer to Periodic Maintenance 8000 YRM 1472. 1. Move the lift truck to a safe, level area and completely lower the mast. Turn the key switch to the OFF position and attach a DO NOT OPERATE tag to the control handle. Block the wheels to prevent unexpected movement. See Periodic Maintenance 8000 YRM 1472, How to Put a Lift Truck on Blocks. 2. Disconnect the battery power cable connector from the truck connector located on the right side of the frame. Pull the battery cable connector handle to separate the battery connector from the truck connector. 3. Remove the electrical compartment cover and open the drive unit compartment doors. 4. Disconnect the brake wiring harness from the main wiring harness near the brake assembly. 5. Remove the brake protective cover by removing the capscrew, washer, and rubber seal from the outside of the cover. 6. Remove the capscrews, lockwashers, and washers securing the brake assembly to the drive motor.

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

DUST COVER ELASTOMERE DUST COVER CAPSCREW WASHER CAPSCREW LOCKWASHER WASHER BRAKE RETAINING RING BRAKE HUB WOODRUFF KEY TRACTION MOTOR

Figure 7. Brake Assembly

5


Operational Check

1800 YRM 1463

8. Remove the retaining ring securing the hub to the motor shaft. 9. Remove the hub from the motor shaft. Recover the Woodruff key.

INSTALL 1. Install the Woodruff key to the motor shaft. Align the groove in the hub with the Woodruff key and Install the hub onto the motor shaft. 2. Install the retaining ring onto the motor shaft to secure the hub. 3. Position the brake assembly onto the hub. Align the brake mounting slots with the mounting holes in the motor housing (as removed) and secure using the capscrews, lockwashers, and washers. See Figure 7.

4. Install the brake protective cover by positioning the cover onto the brake and installing the washer, capscrew and rubber seal. 5. Connect the brake wiring harness to the main wiring harness as removed. 6. Connect the battery and turn key switch to the ON position. Slowly move the control handle to activate traction controls and listen for the electric brake to disengage. Return the control handle to neutral and listen for the electric brake to engage. Check the lift truck for proper operation. 7. Secure the drive unit compartment doors closed. Remove the DO NOT OPERATE tag from the control handle and remove the blocks from drive wheel.

Operational Check WARNING

4. Truck should stop abruptly.

The operational check must be done in an open area with no personnel in the area of the truck.

5. Visually check brake for damage. If no damage is apparent, proceed to the next step.

After removing or replacing the electric brake, the unit should be checked for operation as follows:

6. Turn the key switch to the OFF position and back to the ON position and restart the truck.

1. Start truck and drive it at a very slow speed, with forks trailing.

7. Operate the truck at full speed with unloaded forks trailing.

2. Check for proper release of brake. When travel is requested by moving control handle forward slightly, a slight metallic click should be heard in area of brake assembly to indicate that it has been energized. Truck should move forward smoothly at this time.

8. Push the red emergency disconnect button. This will instantly de-energize the brake and cause it to apply.

3. Push the red emergency disconnect button. This will instantly de-energize the brake and cause it to apply.

6

9. Truck should stop in 9 to 12 feet. NOTE: Driving the truck, then releasing the foot switch, does not engage the brake because the drive motor goes into regenerative mode and stops the truck without the brake.


1800 YRM 1463

Troubleshooting

Troubleshooting PROBLEM Brake does not release.

Brake does not hold truck loaded to capacity on 10% grade.

Brake will not apply.

POSSIBLE CAUSE

PROCEDURE OR ACTION

Key switch is in the OFF position.

Turn the key switch to the ON position.

Battery is not connected or properly charged.

Connect or clean the battery connections. Charge if necessary.

A handrail on the operator’s compartment is raised.

Pull the handrail down into the operating position.

Brake switch assembly is defective.

Replace the brake switch assembly. See Electrical System 2200 YRM 1467 or Electrical System 2200 YRM 1468.

Brake coil open circuit.

Measure coil resistance. See Table 1 for specifications. If resistance is above specification, replace the brake assembly.

Brake coil has shorted to frame or between the windings.

Measure coil resistance. See Table 1 for specifications. If resistance is below specification, replace the brake assembly. Check coil for short to frame using an ohmmeter. If shorted to frame, replace the brake assembly.

Incorrect or no voltage supplied to brake.

Measure voltage to brake using a voltmeter. If voltage is not 24 VDC Âą10%, troubleshoot brake wiring. Troubleshoot electrical system and controller.

Air gap is too large.

Replace the brake assembly.

Friction disk is too worn.

Replace the brake assembly.

Brake hub damaged.

Replace brake and hub assembly.

Mechanical failure within the brake assembly.

Replace the brake assembly.

Brake linings worn beyond specification.

Replace the brake assembly.

7


NOTES ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

8


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Yale (a497) fs030bf lift truck service repair manual  
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