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)

 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................................................................................................................................................................ 1
Description .......................................................................................................................................................... 1
Frame Repair....................................................................................................................................................... 2
Remove and Disassemble .............................................................................................................................. 2
Covers, Panels, and Plates ............................................................................................................................. 2
Caster and Caster Wheels .............................................................................................................................. 2
Description.................................................................................................................................................. 2
Caster, Replace .......................................................................................................................................... 3
Caster Wheels, Replace ............................................................................................................................. 3
Painting Instructions ............................................................................................................................................ 4
Label Replacement.............................................................................................................................................. 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 panels. The outer channel of the upright is part of the
frame. Parts include the frame weldment, doors, bat- lift truck frame. The base arms are part of the weldment
tery rollers, covers, casters, caster wheels and battery 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. STUD 9. THUMB SCREW
2. SPRING 10. LH DOOR
3. CUPPED WASHER 11. BATTERY ROLLER
4. RETAINER 12. BATTERY PANEL
5. NUT 13. BASE ARM WELDMENT (OS030BE, OS030BF,
6. COVER OS030EC, AND OS030EF SHOWN)
7. HINGE PIN 14. FRAME WELDMENT
8. RH DOOR

Frame Repair
REMOVE AND DISASSEMBLE The drive wheel of the master drive unit is the other sup-
port for this end of the lift truck. The axle of the caster
WARNING is an articulated axle. The articulated axle permits both
wheels of the caster to always have equal weight. This
Forklift truck frames and components may have
allows for better operation and wear. The caster is fas-
polyurethane paint. Welding, burning, or other heat
tened to the frame weldment by four capscrews and
sufficient to cause thermal decomposition of the
lockwashers. The complete caster can be replaced as a
paint may release isocyanates. These chemicals
unit, or the wheels can be replaced. Always replace the
are allergic sensitizers to the skin and respira-
wheels as a set for better caster operation and wheel
tory tract; overexposure may occur without odor
wear. A single new wheel of the set will wear rapidly.
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.

There is very little repair required on the frame. See Fig-

ure 1. Most repairs can be done by removing the nec-
essary 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, Re-
pair 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 weld-
ment. Two doors provide access to the electrical and
hydraulic compartments. The panels at each end of 1. FRAME WELDMENT
2. CASTER ASSEMBLY
the battery compartment can be removed by lifting them 3. LOCKWASHER
straight up and out of the slots in the frame. 4. CAPSCREW

CASTER AND CASTER WHEELS Figure 2. Caster (SS030BE and SS030BF)

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

2
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 Mainte-
nance 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).
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 Mainte-
nance 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 Pe-
riodic Maintenance 8000 YRM 924 or Periodic
Maintenance 8000 YRM 1472. Install the bearings
in the replacement wheels.

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.
4. Install the guard washers on both sides of the bear-
ing 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.

1. CASTER WHEEL 5. LOCKWASHER

2. AXLE 6. NUT
3. GUARD WASHERS 7. COTTER PIN
4. BEARING

Figure 3. Caster Wheels

3
Label Replacement
Painting Instructions
WARNING
To avoid personal injury, always use solvents and
paints in an area with ventilation. Do not use sol-
vents or paints near heat, fire, or electrical equip-
ment that can make sparks. Follow the manufac-
turer’s instructions and cautions.
CAUTION
Do not paint the pads, plastic covers, knobs, ca-
bles, 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
Label Replacement
WARNING
To avoid personal injury or property damage, labels
that have warnings or instructions that are dam-
aged must be replaced immediately.
If the labels or information plates are missing or have
damage, they must be replaced. See Figure 4 or Fig-
ure 5 for label and plate loctaions.
NOTE: The nameplate is installed using rivets. The old
rivets must be removed before installing a new name-
plate or to change the nameplate information.
4
100 YRM 760
solvent for painted surfaces. Do not use solvent on
new paint.
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 ap-
plying the coat of paint.
3. Protect all surfaces that will not be painted.
4. Paint the surfaces. Use the correct Yale paint. Fol-
low the directions on the container. Contact your
Yale dealer for the correct arrangement of the paint
colors.
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 Label Replacement

1. YALE NAMEPLATE 12. COVER

2. YALE LABEL 13. RIVET
3. YALE LABEL 14. MAST WARNING LABEL
4. ACCENT STRIPE LABEL 15. CAPACITY NAMEPLATE
5. MANUAL LOWERING LABEL 16. COVER
6. MANUAL LOWERING LABEL 17. RIVET
7. OPERATOR WARNING LABEL 18. MULTIFUNCTION CONTROL LABEL
8. OVERHEAD GUARD WARNING PLATE 19. PATENTS AND TRADEMARKS LABEL
9. IGNITION SWITCH LABEL 20. UL PLATE
10. FORK WARNING LABEL 21. OPERATING MANUAL
11. BASE 22. 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. NAMEPLATE 16. MANUAL LOWERING VALVE LOCATION LABEL
2. YALE DECAL 17. INSTRUMENT PANEL LABEL
3. YALE DECAL 18. ACCENT STRIPE LABEL
4. IMPACT RATING PLATE 19. COLD STORAGE LABEL
5. KEY SWITCH LABEL 20. SUBZERO LABEL
6. INFO CASE BASE 21. U.L. INSPECTION LABEL
7. INFO CASE COVER 22. EE IDENTIFICATION MARKER
8. RIVET 23. BATTERY NOTICE LABEL
9. CAPACITY NAMEPLATE 24. MAST WARNING LABEL
10. NAME PLATE COVER 25. PINCH POINT LABEL
11. RIVET 26. MAST WARNING LABEL
12. MULTI FUNCTION CONTROL LABEL 27. OPERATOR WARNING LABEL
13. PATENTS AND TRADEMARKS LABEL 28. WARNING LABEL
14. GREENVILLE MANUFACTURING LABEL 29. NAMEPLATE TAG LABEL
15. MANUAL LOWERING VALVE LABEL 30. 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................................................................................................................................................................ 1
Special Precautions............................................................................................................................................. 2
Description .......................................................................................................................................................... 3
Repair .................................................................................................................................................................. 4
Air Gap ............................................................................................................................................................ 4
Remove ........................................................................................................................................................... 5
Install............................................................................................................................................................... 6
Operational Check............................................................................................................................................... 6
Troubleshooting ................................................................................................................................................... 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 Electri-
cal 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 compart-
ment 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
4. Discharge the capacitors in the controllers by con-
WARNING necting a 200-ohm, 2-watt resistor across the con-
The capacitor in the transistor controller can hold troller’s B+ and B terminals. See Figure 2. DO
an electrical charge after the battery is discon- NOT short across the motor controller terminals
nected. To prevent electrical shock and personal with a screwdriver or jumper wire.
injury, discharge the capacitor before inspecting
or repairing any component. Wear safety glasses. 5. Remove the 200-ohm, 2-watt resistor. Reinstall
Make certain the battery has been disconnected. the electrical compartment cover when repairs are
Discharge the capacitors in the controller by con- complete.
necting a 200-ohm, 2-watt resistor across the
controller’s B+ and B terminals with insulated
jumper wires. DO NOT use a screwdriver to dis-
charge the traction motor controller.

To avoid personal injury and prevent electrical

shock, perform the following steps before per-
forming 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 dis-
connected. 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 com-

pletely lower the mast. Turn the key switch to the
1. NEGATIVE CONNECTION
OFF position and attach a DO NOT OPERATE tag 2. POSITIVE CONNECTION
to the control handle. Block the drive wheel to pre- 3. INSULATED JUMPER WIRES
vent unexpected movement. See How to Put a 4. 200-OHM, 2-WATT RESISTOR
Lift Truck on Blocks in Periodic Maintenance 8000
YRM 1472. Figure 2. Discharging the Controller

2. Disconnect the battery.

3. Remove the electrical compartment cover to ac-

cess the controller.

2
1800 YRM 1463 Description

Description
The electric brake is located in the drive unit com- The master controller breaks the power supply to the
partment mounted to the top of the traction motor. It brake coil, to engage the electric brake when the truck
consists of a spring-applied, electrically-released brake is stopped. Pressing the emergency disconnect switch
mounted directly to the drive motor. See Figure 3. will engage the electric brake immediately in any mode
of operation. The electric brake may be manually dis-
engaged for towing by inserting two standard 1/4-20 ×
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
1. SERVICE CAPSCREWS
Figure 3. Brake Location 2. SERVICE PORTS
3. BRAKE ASSEMBLY
The electric brake is controlled by the master controller. 4. ASSEMBLY HOLES
After receiving input signals from the floor switches and
a traction input from the multifunction control handle, Figure 4. Manual Disengage
the master controller will complete the circuit to pro-
vide power to the brake coil, disengaging the brake.

3
Repair 1800 YRM 1463

Repair
AIR GAP or releasing before the other due to internal dam-
age or tampering. Replace the entire brake assem-
CAUTION bly. Refer to the Remove section in this manual.
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 loca-
tion references only.

1. Check the three outer socket head screws for ap-

propriate torque to secure the brake to the motor.

2. Check for the correct air gap by measuring the dis-

tance between the bottom of the stator and the top
of the pressure plate with the brake engaged (dis-
connected) 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. Re-
place the entire brake assembly. Refer to the Re-
move section in this manual.

NOTE: During brake operation, the brake should en- 1. STATOR

2. AIR GAP
gage and disengage with a solid, single-click noise. 3. PRESSURE PLATE
4. FEELER GAUGE
6. Listen to verify the brake engages and disengages
in one smooth operation. A double-clicking noise Figure 5. Air Gap
indicates that one side of the brake disc is applying
Table 1. Specifications

Air Gap Mounting Minimum Friction

Truck Model
Min Max Capscrews Torque Disk Thickness

FS/OS/SS030BF/ 0.20 mm (0.008 in.) 0.40 mm (0.016 in.) 10.8 N•m (8 lbf ft) 8.50 mm (0.33 in.)
OS030EF

4
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 instal-
lation 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 com-

pletely 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 pre-
vent unexpected movement. See Periodic Main-
tenance 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 con- 1. DUST COVER
nector. 2. ELASTOMERE DUST COVER
3. CAPSCREW
3. Remove the electrical compartment cover and 4. WASHER
open the drive unit compartment doors. 5. CAPSCREW
6. LOCKWASHER
4. Disconnect the brake wiring harness from the main 7. WASHER
wiring harness near the brake assembly. 8. BRAKE
9. RETAINING RING
10. BRAKE HUB
5. Remove the brake protective cover by removing the
11. WOODRUFF KEY
capscrew, washer, and rubber seal from the outside 12. TRACTION MOTOR
of the cover.
Figure 7. Brake Assembly
6. Remove the capscrews, lockwashers, and washers
securing the brake assembly to the drive motor.

5
Operational Check
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 se-
cure 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 Fig-
ure 7.
Operational Check
WARNING
The operational check must be done in an open area
with no personnel in the area of the truck.
After removing or replacing the electric brake, the unit
should be checked for operation as follows:
1. Start truck and drive it at a very slow speed, with
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.
3. Push the red emergency disconnect button. This
will instantly de-energize the brake and cause it to
apply.
6
1800 YRM 1463
4. Install the brake protective cover by positioning the
cover onto the brake and installing the washer, cap-
screw 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 con-
trol handle and remove the blocks from drive wheel.
4. Truck should stop abruptly.
5. Visually check brake for damage. If no damage is
apparent, proceed to the next step.
6. Turn the key switch to the OFF position and back to
the ON position and restart the truck.
7. Operate the truck at full speed with unloaded forks
trailing.
8. Push the red emergency disconnect button. This
will instantly de-energize the brake and cause it to
apply.
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
PROBLEM POSSIBLE CAUSE
Brake does not release. Key switch is in the OFF position.
Battery is not connected or properly
charged.
A handrail on the operator’s compart-
ment is raised.
Brake switch assembly is defective.
Brake coil open circuit.
Brake coil has shorted to frame or be-
tween the windings.
Incorrect or no voltage supplied to
brake.
Brake does not hold truck Air gap is too large.
loaded to capacity on 10%
grade.
Friction disk is too worn.
Brake hub damaged.
Brake will not apply. Mechanical failure within the brake as-
sembly.
Brake linings worn beyond specifica-
tion.
Troubleshooting
PROCEDURE OR ACTION
Turn the key switch to the ON position.
Connect or clean the battery connec-
tions. Charge if necessary.
Pull the handrail down into the operat-
ing position.
Replace the brake switch assembly.
See Electrical System 2200 YRM
1467 or Electrical System 2200 YRM
1468.
Measure coil resistance. See Ta-
ble 1 for specifications. If resistance is
above specification, replace the brake
assembly.
Measure coil resistance. See Table 1
for specifications. If resistance is be-
low specification, replace the brake as-
sembly.
Check coil for short to frame using an
ohmmeter. If shorted to frame, replace
the brake assembly.
Measure voltage to brake using a volt-
meter. If voltage is not 24 VDC ±10%,
troubleshoot brake wiring.
Troubleshoot electrical system and
controller.
Replace the brake assembly.
Replace the brake assembly.
Replace brake and hub assembly.
Replace the brake assembly.
Replace the brake assembly.
7
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