Maintenance
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OS030EC [C801];
OS/SS030BE [D826]
PART NO. 524164051 2200 YRM 957
SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fas-
tened, 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 condition that can cause immediate death or injury!
CAUTION
Indicates a condition that can cause property damage!
Wire Guidance Table of Contents
TABLE OF CONTENTS
General................................................................................................................................................................ 1
Guidance Switch Replacement ........................................................................................................................... 2
Sensors Replacement ......................................................................................................................................... 2
This section is for the following models:
OS030EC [C801];
OS/SS030BE [D826]
©2002 Yale Materials Handling Corp. i
2200 YRM 957 General
General
This manual has the procedures for the replacement of NOTE: Removal and repair procedures for the Mas-
the wire guidance system parts. ter Drive Unit (MDU) are in the section Master Drive
Unit 630 YRM 1021. All mechanical parts of the steer-
NOTE: This lift truck can be operated with the operator ing must be in good condition and correctly adjusted
facing the steer tire or the operator facing the load forks. for correct wire guidance operation. The load wheels
Throughout this manual, the terms right, left, front, and MUST BE THE SAME SIZE and in good condition, and
rear relate to the viewpoint of an operator standing in the bearings must be lubricated and correctly adjusted.
the truck facing the steer tire. See Figure 1.
A. FORWARD DIRECTION OF TRAVEL B. REVERSE DIRECTION OF TRAVEL
1. GUIDE WIRE 3. GUIDANCE SENSOR
2. LOAD WHEEL 4. STEER TIRE
Figure 1. Guidance System Operation
1
Sensors Replacement 2200 YRM 957
Guidance Switch Replacement
NOTE: Removal of each part is usually not necessary. 4. To replace the switch, put tags on the wires for cor-
Remove only the parts necessary to replace the defec- rect connection during installation. Pull the wire ter-
tive part. The guidance switch is located in the instru- minals off the switch terminals.
ment panel.
5. Push the switch assembly out of the instrument
1. Disconnect the battery so the connector is com- panel. Push the replacement switch into the instru-
pletely free. ment panel. Make sure the words on the switch are
not upside down.
2. Remove the screw that fastens the steering handle
(RTC) or steering wheel (MTS) to the shaft of the 6. Close the instrument panel and tighten the screws.
steering mechanism. Remove the steering handle. Install the steering handle on the shaft of the steer-
ing mechanism. Tighten the screw.
3. Remove the screws at the top of the instrument
panel. Tilt the instrument panel to the open posi-
tion for access to the parts.
Sensors Replacement
NOTE: Each sensor must have a cable of the correct
length. New sensors have either a long (load wheel) or CAUTION
short (steer wheel) cable. Make sure to choose the sen- The position of motor and power cables can
sor with the correct cable length during replacement. change the operation of the guidance system. DO
NOT change the position of power cables during
the replacement of sensors.
WARNING
To replace the load wheel sensor, the operator plat- 2. Remove all the cable ties and clamps that fasten
form must be raised to provide access to the sen- the sensor cable. Note the location of each cable tie
sor. The lowering of the operator platform or forks and position of the sensor cable for the installation.
can cause an injury. Use blocks and chains on the
mast and operator platform so they cannot move. 3. Remove the two capscrews and washers that fas-
Make sure the moving parts are attached to a part ten the sensor to the bracket. Remove the sensor.
that cannot move. 4. Install the correct replacement sensor as shown in
Figure 2. The cable for the load wheel sensor is
CAUTION longer than the cable for the steer wheel sensor. If
The electronic components can be damaged by necessary, loosen the capscrews and nuts at the
electrostatic discharge. Use a special floor pad to end of the sensor bracket to align the center mark
help prevent an electrostatic charge. ALWAYS re- on the sensor board. Fasten the sensor so the floor
move the electrostatic charge on your body before clearance is 66.5 mm (2.62 in.).The center mark on
touching electronic components. Connect a static the sensor must align with the centerline of the lift
strap to your wrist and a good earth ground. Follow truck. Tighten the sensor mount capscrews care-
the directions on the package of the component. fully. Do not overtighten the sensor’s screws, as
this may cause damage to the sensor.
1. Raise the operator platform for access to the load
wheel sensor area between the load wheels. Use 5. Install new cable ties at the same locations of the
blocks and chains on the mast and operator plat- old cable ties. Install the cable clamp near the sen-
form so they cannot move. Make sure the moving sor.
parts are attached to a part that cannot move. It
may be necessary to remove the battery for access 6. Connect the sensor connector plug to the correct
to the cable ties and wires from the load wheel sen- sensor socket on the wire guidance controller. This
sor. is done by connecting the load wheel sensor to
the Rear Antenna socket and connecting the steer
wheel sensor to the Front Antenna socket. Connect
the battery connector.
2
2200 YRM 957 Sensors Replacement
NOTE: Do not splice sensor leads. Splicing sensor 7. Remove the support or chain and lower the op-
leads can cause erratic guidance operation. Any time a erator platform. Install the electrical compartment
sensor lead is damaged, install a new, complete sensor cover.
assembly.
1. NUT 7. ANGLE BRACKET 13. SENSOR - FRONT
2. LOCKWASHER 8. LOCKWASHER 14. SENSOR - REAR
3. WASHER 9. NUT 15. ANGLE
4. BAR 10. SCREW 16. CAPSCREW
5. CAPSCREW 11. LOCKWASHER 17. CABLE
6. WASHER 12. LOCKWASHER
Figure 2. Sensor Arrangement
3
NOTES
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Yale Materials Handling Corp.
1400 Sullivan Dr., Greenville, NC 27834-2011
2200 YRM 957 7/02 Printed in U.S.A.
