Maintenance
MAST
REPAIR
SS030BF [A474]; FS030BF [A497];
OS030EC [C801]; OS030EF [D801];
OS/SS030BE [D826]; OS030BF [E826]
PART NO. 524164053 4000 YRM 764
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.
• Alwaysfasten 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.
Mast Table of Contents
TABLE OF CONTENTS
General ................................................................................................................................................................ 1
Forks.................................................................................................................................................................... 1
Replace ........................................................................................................................................................... 1
Operator Platform ................................................................................................................................................ 3
Remove ........................................................................................................................................................... 3
Install ............................................................................................................................................................... 5
Two-Stage Mast ................................................................................................................................................... 5
Remove ........................................................................................................................................................... 5
Disassemble.................................................................................................................................................... 6
Clean and Inspect ........................................................................................................................................... 8
Lift Cylinders ................................................................................................................................................... 10
Assemble ........................................................................................................................................................ 10
Install ............................................................................................................................................................... 10
Three-Stage Mast ................................................................................................................................................ 13
Remove ........................................................................................................................................................... 13
Disassemble.................................................................................................................................................... 13
Clean and Inspect ........................................................................................................................................... 15
Lift Cylinders ................................................................................................................................................... 15
Assemble ........................................................................................................................................................ 15
Install ............................................................................................................................................................... 16
Load Wheels Replacement ................................................................................................................................. 16
Lift System Leak Check ....................................................................................................................................... 17
Lift Chain Adjustment .......................................................................................................................................... 17
Mast Adjustments ................................................................................................................................................ 18
Operator Platform Adjustment ............................................................................................................................. 19
Troubleshooting ................................................................................................................................................... 20
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
4000 YRM 764 Forks
General
This manual has the repair procedures for the two-stage
and three-stage masts. A section for troubleshooting
and a section for checks and adjustments is given at
the end of the section. The description and operation
of the masts are given in the section MAST, Descrip-
tion 4000 YRM 763. Repair procedures for the operator
platform are also in this section.
Forks
REPLACE
WARNING
Lower the lift mechanism completely. Never allow
anyone under a raised operator platform or forks.
Do not put any part of your body in or through the
mechanism unless all parts of the mast are com-
pletely lowered and the key switch is OFF.
Before making any repairs, use blocks and chains
on the mast weldments and operator platform so
they cannot move. Make sure the moving parts are
attached to a nonmoving part.
WARNING
Forks are heavy and can cause an injury. Do not try
to remove forks without using a lifting device.
Each of these forks is connected to the operator plat-
form by a pin near the edge of the platform. See Fig-
ure 1 and Figure 2. The pin fits through a tube welded
to the top of the fork. The forks can be removed by rais-
ing the operator platform for access.
WARNING
Before replacing forks, use blocks and chains on
the mast weldments and operator platform so they
cannot move. Make sure the moving parts are at-
tached to a nonmoving part.
Use blocks and chains to prevent movement of the mast
or operator platform. Support the fork, remove the snap
ring on the end of the pin, and remove the pin. Install the
forks using the reverse procedure. Make sure the hook
at the end of the fork engages the plate of the platform.
Do not install any shims at this time. Make sure the
operator platform is fully lowered. Adjust the lift chains
of the operator platform so the tip of the highest fork is
within the specification. See Lift Chain Adjustment at
the end of this section. After the chains are adjusted,
use shims on the top of the fork (lowest fork tip) at the
hook so the fork tips are aligned within 3.2 mm (1/8 in.).
1. FORK
2. PIN
3. SNAP RING
4. SHIM
5. SPACER
6. WASHER
7. WASHER
Figure 1. Fork Assembly
1
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YALE (C801) OS030EC, (D826) OS/SS030BE Lift Truck Service Repair Manual
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Description
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File Format: PDF
Compatible: All Versions of Windows & Mac
Language: English
Requirements: Adobe Reader & Win
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