Maintenance

PERIODIC
MAINTENANCE
SS030BF [A474];
FS030BF [A497];
OS030EF [D801];
OS030BF [E826]

PART NO. 550032953 8000 YRM 1472

 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.
Periodic Maintenance Table of Contents

TABLE OF CONTENTS

General ..................................................................................................................................................................... 1
How to Move a Disabled Truck .............................................................................................................................1
How to Tow the Lift Truck ................................................................................................................................ 2
How to Put a Lift Truck on Blocks .........................................................................................................................2
How to Raise the Drive Tire ............................................................................................................................. 2
How to Raise the Load Wheels ........................................................................................................................3
Maintenance Schedule ............................................................................................................................................. 4
Maintenance Procedures Every 8 Hours or Daily ...................................................................................................12
How to Make Checks With Key Switch in the OFF Position ...............................................................................12
Hydraulic System ........................................................................................................................................... 12
Battery ............................................................................................................................................................12
Safety Labels ................................................................................................................................................. 13
Mast, Platform, Forks, Lift Chains, and Header Hoses .................................................................................. 13
Inspection of Personal Fall Protection System (PFPS) ..................................................................................14
Pallet Clamp ...................................................................................................................................................14
Tire, Wheels, and Caster ............................................................................................................................... 14
How to Make Checks With Key Switch in the ON Position .................................................................................15
Gauges, Lights, Horn, and Fuses .................................................................................................................. 15
Fuses ............................................................................................................................................................. 15
Direction/Speed, Lift/Lower, and Horn Control ...............................................................................................16
Lift System Operation .....................................................................................................................................17
Parking Brake .................................................................................................................................................18
Steering System .............................................................................................................................................18
Maintenance Procedures Every 350 Hours or 2 Months ........................................................................................ 18
Hydraulics ...........................................................................................................................................................18
Hydraulic Hoses ............................................................................................................................................. 19
Hydraulic Tank Breather ................................................................................................................................ 19
How to Change Hydraulic Oil and Filter ............................................................................................................. 19
Check for Leaks in Lift System ........................................................................................................................... 21
Check Lift Cylinders for Leaks ....................................................................................................................... 21
Electrical Inspection ............................................................................................................................................22
Motor Brushes ................................................................................................................................................22
Caster Wheel ......................................................................................................................................................23
Mast ....................................................................................................................................................................23
Lift Chains ...........................................................................................................................................................23
Electrical Cable Sheaves ....................................................................................................................................25
Master Drive Unit ................................................................................................................................................25
Maintenance Procedures Every 2000 Hours or Yearly ...........................................................................................25
Electrical Inspection ............................................................................................................................................25
Contactors ......................................................................................................................................................25
Master Drive Unit ................................................................................................................................................25
Traction Motor and Input Pinion Splines ........................................................................................................ 25
Wheels and Bearings ......................................................................................................................................... 25
How to Change Hydraulic Oil and Filter ............................................................................................................. 26
Inspection of Personal Fall Protection System ................................................................................................... 28
Battery Maintenance ...............................................................................................................................................28
How to Charge Battery ....................................................................................................................................... 28
How to Change the Battery ................................................................................................................................ 29
General .......................................................................................................................................................... 29
Battery, Remove ............................................................................................................................................ 29

©2014 Yale Materials Handling Corp. i

Table of Contents Periodic Maintenance

TABLE OF CONTENTS (Continued)

Battery, Install ................................................................................................................................................ 30

Wheels and Tires ....................................................................................................................................................31
How to Change Drive and Steer Tires ................................................................................................................31
How to Replace Load Wheels ............................................................................................................................ 32

This section is for the following models:

(SS030BF) [A474];
(FS030BF) [A497];
(OS030EF) [D801];
(OS030BF) [E826]

ii
8000 YRM 1472
General
This manual contains a Maintenance Schedule and
the instructions for maintenance and inspection.
The Maintenance Schedule has time intervals for
inspection, lubrication, and maintenance. The time
intervals are based on a normal operation. A normal
operation is considered to be one 8-hour shift per day,
in a relatively clean environment, on an improved
surface. Multiple shifts, dirty operating conditions,
etc., will require a reduction in the recommended time
periods in the Maintenance Schedule.
Some users have service personnel and facilities to
perform the items listed in the Maintenance Schedule.
Service Manuals are available from your Yale lift truck
dealer to help users who do their own maintenance.
Your Yale lift truck dealer has the personnel and
equipment to do a complete program of inspection,
lubrication, and maintenance. Periodic maintenance
will help your lift truck operate better over a longer
period.
WARNING
DO NOT make repairs or adjustments unless you
have both authorization and training. Repairs and
adjustments that are not correct can be made on a
lift truck by people without authorization and
training. Repairs and adjustments that are not
correct can make a dangerous operating
condition.
DO NOT operate a lift truck that needs repairs.
Report the need for repairs immediately. If repair
is necessary, put a DO NOT OPERATE tag in the
operator's area. Remove the key from the key
switch.
Put the lift truck on a level surface. Lower the platform
and forks, apply the parking brake, and turn the key
switch to the OFF position. Open the access panels
General
and check for leaks and conditions that are not
normal. Clean any oil or other spills. Make sure that
lint, dust, paper, and other materials are removed
from the compartments.
HOW TO MOVE A DISABLED TRUCK
WARNING
To avoid personal injury or property damage, use
extra care when moving a lift truck if there is a
problem with any of the following conditions:
• Brakes do not operate correctly.
• Steering does not operate correctly.
• Tires are damaged.
• Traction conditions are bad.
• The lift truck must be towed on a steep
grade.
Poor traction can cause the disabled lift truck or
towing vehicle to slide. Steep grades will increase
the required brake effort.
NOTE: Always remember there may be problems
with more than one of the above areas of the truck.
DO NOT tow the lift truck if you have not identified all
problem areas.
The best way to move the lift truck is to use another
lift truck to raise the drive tire off the ground. This will
allow the lift truck to be towed or pushed around.
Whatever method is used, the important thing to
remember is to travel slowly.
If there is no electrical power, there is no steering and
the brake will be applied. If the lift truck is inoperable,
the brake will have to be released using two 1/4-20 ×
1-1/2 inch bolts. Poor traction can cause the disabled
lift truck or towing vehicle to slide. Steep grades will
require additional brake force to stop the lift truck.
1
General
Never carry a disabled lift truck unless the lift truck
MUST be moved and cannot be towed. The lift truck
used to lift the disabled lift truck MUST have a rated
capacity equal to or greater than the weight of the
disabled lift truck. The capacity must be for a load
center equal to half the width of the disabled lift truck.
See the nameplate on the disabled lift truck for the
approximate total weight. The forks must extend the
full width of the disabled lift truck. Center the weight of
the disabled lift truck on the forks and be careful not
to damage the underside of the disabled lift truck. Tilt
the mast back and travel slowly.
How to Tow the Lift Truck
CAUTION
DO NOT tow the lift truck by fastening a towing
device to the attachment or base arms. Make sure
the guidance sensors are not damaged when
connecting a chain to the lift truck.
1. If the lift truck must be towed, the operator must
be on the lift truck to release the brake and steer
the lift truck. If the lift truck is inoperable, release
the brake using two 1/4-20 × 1-1/2 inch bolts.
2. Tow the lift truck slowly.
3. Raise the platform approximately 30 cm (12 in.)
from the surface. Install a chain to prevent the
platform and mast channels from moving.
4. If another lift truck that has the drive wheels near
the forks is used to tow the disabled lift truck, that
lift truck must have weight added to the forks. The
total weight of the lift truck and load must be
equal to or greater than the weight of the disabled
lift truck. Install a load of approximately half the
maximum capacity on the forks of the lift truck
that is used for towing. This load will increase the
traction of the lift truck. Keep the load on the forks
lowered as much as possible.
If the lift truck used for towing has a master drive
unit or drive unit similar to the OS030EF or OS/SS/
FS030BF, DO NOT add weight to the forks.
2
8000 YRM 1472
Additional weight on the forks will DECREASE the
traction of the drive wheel(s). Make sure that the lift
truck has a total weight equal to or greater than the
weight of the disabled lift truck.
5. Make sure the tow chain has the capacity to tow
the weight. Carefully fasten the tow chain to the
drive unit end of the lift truck. Make sure the chain
is fastened so that the chain will not cause
damage to either lift truck.
HOW TO PUT A LIFT TRUCK ON BLOCKS
How to Raise the Drive Tire
WARNING
The lift truck must be put on blocks for some
types of maintenance and repair. The removal of
the following assemblies will cause large changes
in the center of gravity: mast, battery, and master
drive unit.
DO NOT put the lift truck on blocks if the surface
is not solid, even, and level. Make sure that any
blocks used to support the lift truck are solid,
one-piece units. Put a block in front and back of
the tires touching the ground to prevent
movement of the lift truck.
DO NOT raise the lift truck by attaching an
overhead crane to the overhead guard or areas of
the mast that will be damaged. Some of these
components and other lift points are not designed
to support the weight of the lift truck. The lift truck
can be damaged or it can fall on someone,
causing serious injury. Attach the chain or sling
to a support structure of the lift truck frame.
CAUTION
Make sure the sensors are not damaged on trucks
that have wire guidance.
1. Put blocks on each side (front and back) of the
load wheels to prevent movement of the lift truck.
See Figure 1.
8000 YRM 1472
1. DRIVE/STEER WHEEL
Figure 1. How to Put Lift Truck on Blocks
2. Use a special low-clearance hydraulic jack, crane,
or another lift truck to raise the drive tire. Make
sure that the jack, crane, or other lift truck has the
correct minimum capacity rating. The capacity
must equal at least 2/3 the weight of the lift truck
including the battery. See the nameplate.
3. Raise the lift truck only enough to suspend the
drive tire. Install additional blocks under the frame
near the drive tire.
How to Raise the Load Wheels
WARNING
Never raise the base arms any higher than
necessary to change the load wheels. Always
raise both base arms at the same time. Raising
the base arms too high can make the lift truck tip
over and cause damage or possible injury.
General
2. LOAD WHEEL
CAUTION
Make sure the sensors are not damaged on trucks
that have wire guidance.
1. Put blocks on both sides (front and back) of the
drive tire to prevent movement of the lift truck.
See Figure 1.
2. Use a hydraulic jack, crane, or another lift truck to
lift the base arms. Make sure that the jack, crane,
or other lift truck has a capacity equal to at least
half the weight of the lift truck including the
battery.
3. Put blocks under the base arm at the rear of the
load wheel to support the lift truck.
3
Maintenance Schedule 8000 YRM 1472

Maintenance Schedule
The Maintenance Schedule has two time periods. If than eight hours each day, perform maintenance at
the lift truck is operated less than eight hours each the periods shown in hours (8, 350, 2000). The ap-
day, perform maintenance at the 1-DAY, 2-MONTHS, proximate locations of the items indicated in the Ta-
and 1-YEAR periods. If the lift truck is operated more ble 1 are shown in Figure 2.

Figure 2. Maintenance Points

4
8000 YRM 1472 Maintenance Schedule

Table 1. Maintenance Schedule

Item Item 8 hr/ 350 hr/ 2000 hr/ Procedure Specification

No. 1 day 2 mo 1 yr or Quantity
Hydraulic System
Oil Leaks X Check Repair or
System for Replace
Leaks Parts as
Necessary

1 Hydraulic Oil Level X C9 C Check Level ISO VG 46

OS030EF: Using above
14.7 liter (3.9 gal) Spyglass 0°C (32°F)
FS030BF: (HCE-140)
29.9 liter (7.9 gal) Exxon Univis
OS/SS030BF: HVI 26 below
30.6 liter (8.1 gal) 0°C (32°F)
2 Breather Cap and Neck X C Clean or See Parts
Strainer Replace Manual
Hydraulic Oil Filter C9 C Change See Parts
Manual
3 Hydraulic Pump/Motor L Clean and Multipurpose
Coupling (FS/OS/ Lube (DC Grease3
SS030BF) Only)
Motor Brushes X Check See Parts
(DC Only) Condition Manual
4 Fittings, Clamps, and X Inspect for Adjust,
Hoses Visual Repair, or
Damage Replace as
Necessary
Battery
Charge State10 X1 Check State See Battery
Maintenance
Cell Inspection10 X Check See Battery
Level / Maintenance
Distilled
Water
5 Battery Connector X Check See Parts
Condition Manual
X=Check C=Change L=Lubricate CIL=Check Indicator Light
NOTE: Never use steam to clean electrical parts or chains.

5
Maintenance Schedule 8000 YRM 1472

Table 1. Maintenance Schedule (Continued)

Item Item 8 hr/ 350 hr/ 2000 hr/ Procedure Specification

No. 1 day 2 mo 1 yr or Quantity
6 Battery Restraints X Check Adjusted,
Condition Secure, and
in Place
7 Battery Disconnect X Disconnects
Switch Power
8 Battery Rollers X, L Rollers Turn Silicon Spray
Freely Lubricant2
Safety Information
Personal Fall X X Replace if See Parts
Protection System Necessary Manual
(PFPS)
Safety Labels10 X Replace if See Parts
Necessary Manual
9 Operating Manual X Replace if See Parts
Necessary Manual
Frame, Covers, and Plates
10 Frame X Visually
Inspect
Welds and
Structure
11 Plastic Covers X Visually See Parts
Inspect for Manual
Damage
12 Operator Mat X Visually See Parts
Inspect for Manual
Damage
Electrical System
Electrical Circuits10 X Check
Operation
Static Strap10 X Check for See Parts
Damage Manual
13 Fuses X Check
Operation /
Replace if
Blown
Contactors X Check
Condition
X=Check C=Change L=Lubricate CIL=Check Indicator Light
NOTE: Never use steam to clean electrical parts or chains.

6
8000 YRM 1472 Maintenance Schedule

Table 1. Maintenance Schedule (Continued)

Item Item 8 hr/ 350 hr/ 2000 hr/ Procedure Specification

No. 1 day 2 mo 1 yr or Quantity
Operator Panel
Lights (Optional)10 X Check
Operation
14 Display X Check
Operation
Steering System
15 Steering Operation X Check No Binding,
(Smart Steer Shown) Operation Smooth
Operation
16 Drive Tire X Check Remove
Condition Imbedded
Objects
Drive Wheel X Check 135 N•m
Torque (100 lbf ft)
Load Wheels X Check
Bearings
Caster Wheel L Lubricate 4 Multipurpose
Fittings per Grease3
Wheel
17 Steer Actuator Bolts X5 Check 19.1 N•m
Torque 3- (169.1 lbf in)
Places
Multifunction Control Handle
18 Directional Control L Check Mobilgrease
Handle Bushing Operation - 28 or
Remove and Equivalent
Lube as
Required
Horn X Check No Binding,
Operation Operates
Proper
Function
Lift Control X Check No Binding,
Operation Operates
Proper
Function
Directional / Speed X Check No Binding,
Control Operation Operates
Proper
Function
Brake System
X=Check C=Change L=Lubricate CIL=Check Indicator Light
NOTE: Never use steam to clean electrical parts or chains.

7
Maintenance Schedule 8000 YRM 1472

Table 1. Maintenance Schedule (Continued)

Item Item 8 hr/ 350 hr/ 2000 hr/ Procedure Specification

No. 1 day 2 mo 1 yr or Quantity
Operation X Check
Operation
19 Parking Brake Hold X Hold Full Stop, Hold,
Rated Load Start with <1"
on 5% Ramp Rollback
20 Foot Switch CIL Dash Display Check for
Indicator Proper
Light Operation
Illuminated
with Foot not
on Switch
Master Drive Unit (Early Production)
21 Internal Function X Check Listen for
Operation Abnormal
Sounds
Seals X Check for Repair as
Leaks Necessary
Fluid Level X, C8 Fill to Bottom Gear Oil6
of Fill Hole
MDU Motor Splines L Apply to Moly Paste7
Internal
Pinion and
External
Motor Shaft
Splines
Ring Gear and Pinion X L Apply to Multipurpose
Gears Grease3
Breather X Clean and Replace as
Check Necessary
Operation
Studs and Lugs X Visually Loose or
Inspect Missing
Studs / Lug
Nuts
Master Drive Unit (Late Production)
X=Check C=Change L=Lubricate CIL=Check Indicator Light
NOTE: Never use steam to clean electrical parts or chains.

8
8000 YRM 1472 Maintenance Schedule

Table 1. Maintenance Schedule (Continued)

Item Item 8 hr/ 350 hr/ 2000 hr/ Procedure Specification

No. 1 day 2 mo 1 yr or Quantity
21 Internal Function X Check Listen for
Operation Abnormal
Sounds
Steering Gear L Apply to Multipurpose
Gear Grease3
Gearcase X Level With Gear
OS030BF Bottom of Oil52.2 liter
(E826) and Check Hole. (2.3 qt)
OS030EF Replace seal
(D801) P/N
(GK - 20) 580017695
and tighten
plug to
30 N•m
(22 lbf ft)
Gearcase X Level With Gear
SS030BF Bottom of Oil53.3 liter
(A474) and Check Hole. (3.5 qt)
FS030BF (A497) Replace seal
(GK - 25) P/N
580017695
and tighten
plug to
30 N•m
(22 lbf ft)
Mast
Pivots, Sliding X L4 Lubricate as Multipurpose
Surfaces, Channels, Required Grease3
and Load Rollers
Slack Chain Switches X Check See Lift
Operation System
Operation
22 MAST Assembly X Inspect for Adjust,
Visual Repair, or
Damage and Replace as
Defects Necessary
X=Check C=Change L=Lubricate CIL=Check Indicator Light
NOTE: Never use steam to clean electrical parts or chains.

9
Maintenance Schedule 8000 YRM 1472

Table 1. Maintenance Schedule (Continued)

Item Item 8 hr/ 350 hr/ 2000 hr/ Procedure Specification

No. 1 day 2 mo 1 yr or Quantity
23 MAST Trunions and X Check Bolt 225 N•m
Lower Mount Torques (166 lbf ft)
24 Lift Chains X, L L Lubricate if SAE 10W-30
Dry or Engine Oil3
Visible Rust
X Check Adjust or
Stretch Replace as
Necessary
X Check Adjust or
Adjustment Replace as
and Length Necessary
L Remove Solvent to
Chains to Clean
Clean and Lubricate with
Lubricate SAE 10W-30
Engine Oil
Sheaves X, L Lubricate as Grease11
Required
Chain Anchors X Check for Repair or
Damage / Replace as
Cotter Pins Necessary
in Place
L Lubricate if SAE 10W-30
Dry or Engine Oil
Visible Rust
Operator Platform and Forks
Base Arm Load Wheel L Lubricate as SAE 10W-30
Pivot Bearings Required Engine Oil
25 Operator Platform X Visually Repair or
Assembly Inspect Replace as
Structure Necessary
and Welds
for Damage
L Lubricate Multipurpose
Load Roller Grease3
Bearings
X=Check C=Change L=Lubricate CIL=Check Indicator Light
NOTE: Never use steam to clean electrical parts or chains.

10
8000 YRM 1472 Maintenance Procedures Every 8 Hours or Daily

Table 1. Maintenance Schedule (Continued)

Item Item 8 hr/ 350 hr/ 2000 hr/ Procedure Specification

No. 1 day 2 mo 1 yr or Quantity
26 Forks X Visually Replace as
Inspect for Necessary
Damage
X Tip Replace as
Alignment / Necessary
Heels within
Spec.
Fork Pins and Guides L Lubricate as SAE 10W-30
Required Engine Oil
27 Pallet Clamp X Inspect for Repair or
Damage and Replace as
Spreading Necessary
X Check Pawl Adjust as
Adjustment Necessary
L Lubricate as Antiseize
Required Lubricant
Miscellaneous L Lubricate as Silicon Spray
Required Lubricant2
1
Equalization charge approximately each month, but not more than each week.
2
Silicone spray lubricant Yale P/N 504236201 or equivalent.
3
Multipurpose lithium complex grease with 2-4% molybdenum disulfide for normal operations.
4
It is recommended to lubricate every 250 hours for the first 1000 hours to maximize surface life.
5
For rough floor applications, this schedule should be shortened to 500 hours or 3 months.
6
Use Yale P/N 310153236 for conditions above 0°C / 32°F. Use Yale P/N 310153228 for conditions below 0°C /
32°F.
7
Use Dow Corning Molykote G-N paste (or equivalent) Yale P/N 580000793 on splines every 3000 hours.
8
Initial change after the first 350 hours. No subsequent change after that for the life of the unit.
9
Initial change after the first 350 hours. Subsequent replacement every 2000 hours (1000 hours / 6 months for
corrosion/freezer option).
10
Not illustrated.
11
Grease P/N 310156242 for above -18°C (0°F). for below -18°C (0°F)
X=Check C=Change L=Lubricate CIL=Check Indicator Light
NOTE: Never use steam to clean electrical parts or chains.

11
Maintenance Procedures Every 8 Hours or Daily
Maintenance Procedures Every 8 Hours or Daily
HOW TO MAKE CHECKS WITH KEY
SWITCH IN THE OFF POSITION
Hydraulic System
WARNING
Always wear the proper protective equipment in-
cluding eye protection and petroleum-resistant
gloves when handling hydraulic oil. Thoroughly
wash oil from exposed areas of skin as soon as
possible.
Completely lower forks to relieve hydraulic pres-
sure before disassembling any part of the lift
pump or disconnecting any hydraulic hoses.
The hydraulic oil is hot at normal operating tem-
peratures. Be careful when draining the oil.
Never check for leaks by putting hands on hy-
draulic lines or components under pressure. Hy-
draulic oil under pressure can be injected into the
skin.
CAUTION
Protect the hydraulic system from dirt and con-
taminants when servicing the hydraulic system.
Never operate the pump without the proper
amount of oil in the hydraulic system. The opera-
tion of the hydraulic pump with low oil levels will
damage the pump.
Park the lift truck on a level surface. Completely lower
the mast and the forks.
Check the hydraulic oil level at the sight gauge when
the oil is at operating temperature. If the oil level is not
visible at the sight gauge, the oil level is above or be-
low the sight gauge. Open the door of the hydraulic
compartment to check for the correct level and fill the
tank if necessary. If too much hydraulic oil is added,
the oil will leak from the breather during operation.
Clean the breather and fill cap by removing the fill cap
and flushing it with solvent. Make sure the breather
and fill cap are free of solvent. Install and tighten the
fill cap.
12
8000 YRM 1472
Inspect all hydraulic hoses and fittings for leaks.
Check for broken or damaged hose clamps. Repair or
replace any components as necessary.
Battery
WARNING
DO NOT lay tools on the battery. Tools on the bat-
tery can cause a short circuit and possible dam-
age or injury.
Wear eye protection. The acid in the electrolyte
can cause injury. If the electrolyte is spilled, use
water to flush the area. Make the acid neutral with
a solution of sodium bicarbonate (baking soda).
Acid in the eyes must be immediately flushed with
water continuously for fifteen minutes, then seek
medical attention.
Batteries generate explosive fumes. Keep the
vents in the caps clean. Keep sparks or open
flames away from the battery area. DO NOT make
a spark from the battery connections. Disconnect
the battery when doing maintenance.
DO NOT put hands, arms, feet, or legs between
the battery and a solid object. Batteries are very
heavy and can cause an injury.
The lift truck and battery stand MUST be on a
level surface to remove the battery.
Remove the battery as described in How to Change
the Battery. Check the battery case, connector, and
cables for damage, cracks, or breaks. See the battery
dealer in your area to repair any damage. Keep the
battery case and the battery compartment clean and
painted. Leaks and corrosion from the battery can
cause a malfunction in the electric controls of the lift
truck. Use a water-and-soda solution to clean the bat-
tery and the battery compartment. Keep the top of the
battery clean, dry, and free of corrosion.
Check the level of the electrolyte daily on a minimum
of one cell. Add only distilled water if the cell is low.
The correct level is halfway between the top of the
plates and the bottom of the fill hole. To check and
add water to the cells, the battery must be out of the
battery compartment.
8000 YRM 1472 Maintenance Procedures Every 8 Hours or Daily

Check that the correct spacer is installed across the

mast side of the battery compartment. The spacer
must allow the battery to move not more than
13.0 mm (0.5 in.) toward the front or rear of the com-
partment. Check that the battery cannot move more
than 13.0 mm (0.5 in.) across the width of the lift
truck. If the battery can move more than the maximum
amount, make sure the battery is the correct weight
and the correct spacers are installed for that battery.
See your Yale lift truck dealer for the correct spacers.
The correct battery is in Table 4 of Battery Mainte-
nance at the end of this section. Check that each bat-
tery compartment panel fits correctly and is not bent.
Safety Labels
WARNING
Safety labels are installed on the lift truck to pro-
vide information about possible hazards. It is im-
portant that all safety labels are installed on the
lift truck and can be read.
CAUTION
DO NOT try to correct alignment of the fork tips
by bending the forks. Use shims to align the fork
tips. Replace damaged forks.
Never repair damaged forks by heating or welding.
Forks are made of special steel using special proce-
dures. Replace damaged forks. Always replace forks
in pairs.
1. Inspect the welds on the mast and platform for
cracks. Make sure the nuts and bolts are tight-
ened.
2. Inspect the channels for wear in the areas where
the rollers travel. Inspect the rollers for wear or
damage.
3. Check all lift chains for the correct lubrication. Lu-
bricate the lift chains using the oil specified in the
Maintenance Schedule .

4. Inspect the lift chains for cracks or broken links

Check that all safety labels are installed in the correct
and pins. See Figure 3.
locations on the lift truck. See the Parts Manual, Op-
erators Manual, or the Frame section for the correct
locations of the safety labels.

Mast, Platform, Forks, Lift Chains, and

Header Hoses

WARNING
To avoid personal injury or property damage,
NEVER work under a raised platform or forks.
Lower the platform or use chains on the mast
weldments and platform so they cannot move.
When chains are used, make sure the moving
parts are fastened to a part that cannot move.

Never repair damaged forks. DO NOT heat, weld,

or bend forks. Replace damaged forks.

Check the attachment points of the forks with a pene-

trant or magnetic particle inspection.
1. WORN PIN 5. LOOSE LEAVES
2. CRACKS 6. DAMAGED PIN
3. EDGE WEAR 7. RUST
4. HOLE WEAR

Figure 3. Inspect Lift Chains and Cables

13
Maintenance Procedures Every 8 Hours or Daily
5. Inspect the chain anchors and pins for cracks or
damage.
6. Make sure the lift chains are adjusted so they
have equal tension. Check tension by pulling hori-
zontally on both chains and checking that they
move the same amount. If the chains need repair
or adjustment, it must be done by authorized per-
sonnel.
1. TIP ALIGNMENT 2. CRACKS
Figure 4. How to Inspect Forks
8. Inspect forks for cracks and wear.
9. Replace any damaged or broken parts that keep
the forks locked in position.
WARNING
Always wear the proper protective equipment in-
cluding eye protection and petroleum-resistant
gloves when handling hydraulic oil. Thoroughly
wash oil from exposed areas of skin as soon as
possible.
Never check for leaks by putting hands on hy-
draulic lines or components under pressure. Hy-
draulic oil under pressure can be injected into the
skin.
10. Inspect the mast header hoses and fittings for hy-
draulic leaks. Check the hose cover for cracks or
exposed reinforcement. Check for broken or de-
fective clamping devices and sheaves. Repair or
replace any damaged components as necessary.
Inspection of Personal Fall Protection System
(PFPS)
WARNING
The Personal Fall Protection is specially made to
lessen the shock of a fall. Do not substitute other
types of ropes or straps.
14
8000 YRM 1472
7. Check that the fork tips are aligned within
13.0 mm (0.5 in.) of each other. See Figure 4.
Add or remove shims for alignment.
3. FORK PIN DAMAGE
1. Inspect the lanyard for wear, deformation, exces-
sive elongation, cuts or damage. Inspect the clips
for cracks, broken hardware, corrosion, and
proper operation. Replace as necessary.
2. Inspect the full body harness or body belt for fray-
ing, cracks, cuts, deformation or wear. Inspect
any hardware for cracks, broken hardware, corro-
sion and proper operation. Replace as necessary.
Pallet Clamp
Check for correct operation of the pallet clamp. Put an
empty pallet on the forks. With the forks raised so the
pallet is supported by the forks, stand on the corners
of the pallet farthest from the operator's platform.
Some movement may occur, but the board under the
opposite fork must not raise enough to contact the
fork. Use antiseize lubricant to lubricate the pawls of
the pallet clamp.
Tire, Wheels, and Caster
Inspect the drive tire and load wheels for damage. In-
spect the tread and remove any objects that will
cause damage. See Figure 5. Smooth any cuts or
tears to prevent further damage. Inspect the wheels
and caster for loose or missing parts. Remove any
wire, strapping, or other material wound around the
axles or caster.
8000 YRM 1472
CAUTION
If the wheels have been removed and installed,
check all wheel nuts after 2 to 5 hours of opera-
tion. Tighten the nuts (in a cross pattern) to the
correct torque value shown in the Maintenance
Schedule table. When the nuts stay tight after 8
hours, the interval for checking the torque can be
extended to 2000 hours.
Make sure the wheel nuts are tightened to the correct
torque value. Tighten the nuts (in a cross pattern) to
the correct torque value shown in the Maintenance
Schedule table.
1. REMOVE NAILS, GLASS, AND ALL METAL
2. MAKE SMOOTH EDGES
Figure 5. Inspecting Tire and Wheels
HOW TO MAKE CHECKS WITH KEY
SWITCH IN THE ON POSITION
Gauges, Lights, Horn, and Fuses
WARNING
Make sure the area around the lift truck is clear
before moving the lift truck or checking for cor-
rect operation. Be careful to avoid injury or dam-
age when making the checks.
NOTE: None of the electrical controls will operate un-
til the power disconnect circuit is energized by the key
switch. See Figure 2 and Table 1.
Maintenance Procedures Every 8 Hours or Daily
Check that all the instruments and controls operate as
described in the Operating Manual. Check the oper-
ation of the gauges and horn. The key switch must be
in the ON position to operate the horn. The key switch
must be in the ON position for the hourmeter to oper-
ate. The battery meter operates whenever a charged
battery is connected.
The battery meter correctly indicates the condition of
the battery. If the battery meter LED is illuminated red,
charge the battery. There must be a current flow from
the battery before the lift interrupt indicator will be re-
set. Normal operation, after connecting a charged bat-
tery, will reset the indicator.
Fuses
There are five fuses on these trucks and they are all
found on the contactor panel. Ratings of the fuses are
shown in Table 2.
Table 2. Fuses
Fuses Circuit Rating
FU 1 Operator Compartment 10A
FU 2 Optional Equipment 10A
FU 3 Control Compartment 10A
FU 4 Spare 10A
FU 5 Hydraulic Pump 300A
(OS030EF)
500A
(OS/SS/
FS030BF)
Power to the key switch is supplied by FU 1. If FU 1 is
blown, the truck will not power up. FU 3 supplies key
switch power to the traction controller. Without this
current, the controller will be disabled and will not al-
low the drive motor to work.
All the fuses are located in the electrical compart-
ment. See Figure 6, Figure 7, or Figure 8. Remove
the cover over the electrical compartment for access.
The condition of some fuses can be checked by look-
ing at them. Other fuses do not change in looks and
must be checked with an ohmmeter to determine con-
tinuity. Disconnect the battery before checking fuses.
Check that the fuses are the correct sizes and are not
burned. Some types of fuses must be checked with
an ohmmeter. If any of the fuses are bad, disconnect
the battery before replacing the fuse.
15
Maintenance Procedures Every 8 Hours or Daily 8000 YRM 1472

Legend for Figure 7

1. FUSE 1 4. FUSE 4
2. FUSE 2 5. FUSE 5
3. FUSE 3

1. FUSE 1 4. FUSE 4
2. FUSE 2 5. FUSE 5
3. FUSE 3

Figure 6. 24-Volt Fuse Locations (OS030EF)

NOTE: FUSES 1 THROUGH 4 ARE POSITIONED

THE SAME AS FIGURE 6 AND FIGURE 7.

1. FUSE 1 (NOT SHOWN)

2. FUSE 2 (NOT SHOWN)
3. FUSE 3 (NOT SHOWN)
4. FUSE 4 (NOT SHOWN)
5. FUSE 5 (NOT SHOWN)
6. FUSE BOX
7. FUSE COVER

Figure 8. 24/36-Volt EE Fuse Locations

(OS/SS/FS030BF)

Direction/Speed, Lift/Lower, and Horn Control

Check that the direction/speed, lift/lower, and horn

control operate as described in Table 1 of the Operat-
ing Manual. Check that the foot switch and direction/
speed control operate as described in the Operating
Procedures section of the Operating Manual.

Figure 7. 24/36-Volt Fuse Locations

(OS/SS/FS030BF)

16
8000 YRM 1472 Maintenance Procedures Every 8 Hours or Daily

Check the operation of the battery disconnect switch. the foot switch depressed. All electrical circuits must
The location of the switch is shown in Figure 9. Push NOT operate. Move the key to the OFF and ON posi-
the switch with the key switch in the ON position and tions to reset the battery disconnect circuit.

1. STEERING CONTROL (SMART STEER SHOWN)

2. PLUG (OPTIONAL CONSOLE ADJUSTMENT RELEASE)
3. DASH DISPLAY
4. LIFT/LOWER SWITCH (OPTIONAL)
5. BODY FAN SWITCH (OPTIONAL)
6. WIRE GUIDANCE SWITCH (OPTIONAL)
7. BATTERY DISCONNECT SWITCH
8. KEY SWITCH
9. DIRECTION/SPEED CONTROL ASSEMBLY

Figure 9. Instruments and Controls

Lift System Operation
WARNING
Lower the lift mechanism completely. Never allow
anyone under a raised platform or forks. DO NOT
put any part of your body in or through the lift
mechanism unless all parts of the mast and plat-
form are completely lowered and the key switch is
in the OFF position. Remove the key.
Before making any repairs, completely lower the
platform or use chains on the mast weldments
and platform so they cannot move. Make sure the
moving parts are fastened to the parts that cannot
move.
Never check for leaks by putting hands on hy-
draulic lines or components under pressure. Hy-
draulic oil under pressure can be injected into the
skin.
1. Check for leaks in the hydraulic system. Check
the condition of the hydraulic hoses and tubes.
2. Slowly raise and lower the forks and the platform
several times without a load. All moving compo-
nents must raise and lower smoothly.
3. The platform and the forks must lower completely.
4. Raise the platform 1 m (3 ft) with a capacity load.
The inner weldment and platform must raise
smoothly. Lower the platform and forks. All mov-
ing components must lower smoothly.

17
Maintenance Procedures Every 350 Hours or 2 Months 8000 YRM 1472

5. Make sure the tops of the forks are 70 to 1525 mm (60 in.) is 9.7 km/h (6.0 mph) for the
76 mm (2.75 to 3.00 in.) above the floor on the OS030EF and 10.5 km/h (6.5 mph) for models
R30XM3, R30XMS3, and R30XMA3 FS/OS/SS030BF.

For R30XMF3 the tops of the forks are 159 to 8. If necessary, have the lift truck checked and ad-
171 mm (6.25 to 6.75 in.) above the floor. justed by authorized service personnel.

If the clearance is not correct, the chain anchors Parking Brake

must be adjusted.
Check the operation of the parking brake. The parking
6. Check for proper operation of Lowering Interrupt
brake will hold the lift truck with a capacity load on a
Switches by positioning the forks over an empty
5% grade [a slope of 0.5 m in 10 m (1.6 ft in 33 ft)]. If
pallet on the floor and lowering the forks onto the
the parking brake does not hold the lift truck on the
pallet to relax the chains. As the chains are re-
grade, the parking brake needs to be checked by au-
laxed, the Lowering Interrupt Switches signal the
thorized service personnel. See the section Brake
controller that the chains have become slack. A
System 1800YRM1463 to check or repair the parking
warning (Slack Chains) will be displayed on the
brake.
display, and traction and lowering functions will be
suspended until the platform is lifted to a point
Steering System
where the chains are under proper tension. If low-
ering the forks onto the pallet does not activate
the Lowering Interrupt Switches, the lift truck WARNING
should be removed from service and repaired by There is NO steering if there is no electrical
a properly trained service technician. power. To prevent injury or damage, make sure
the electric power steering is operating correctly
7. Check the operation of the limit switches on the
before moving the lift truck.
mast. The travel speed is directly proportional to
the height of the forks and the steer angle. The
Make sure that the steering system operates
maximum travel speed must be slower when the
smoothly and has good steering control.
platform is above 1525 mm (60 in.). Maximum
travel speed with the platform below

Maintenance Procedures Every 350 Hours or 2 Months

NOTE: Perform the following procedures in addition
to the 8-hour checks.
HYDRAULICS
WARNING
Always wear the proper protective equipment
icluding eye protection and petroleum-resistant
gloves when handling hydraulic oil. Thoroughly
wash oil from exposed areas of skin as soon as
possible.
Completely lower forks to relieve hydraulic pres-
sure before disassembling any part of the lift
pump or disconnecting any hydraulic hoses.
CAUTION
Protect the hydraulic system from dirt and con-
taminants when servicing the hydraulic system.
In addition to the daily inspections, the following tasks
must be performed:

Never check for leaks by putting hands on hy-

draulic lines or components under pressure. Hy-
draulic oil under pressure can be injected into the
skin.

18
8000 YRM 1472 Maintenance Procedures Every 350 Hours or 2 Months

Hydraulic Hoses
Inspect all hydraulic hoses for kinks. Verify that there
are no crushed, flattened, or twisted hoses. Check for
hard, stiff, or charred hoses. Adjust or replace any ho-
ses as necessary.
Hydraulic Tank Breather
The fill cap and breather assembly are in the hy-
draulic compartment at the top of the hydraulic tank.
See the section How to Change Hydraulic Oil and Fil-
ter. Remove the fill cap assembly from the hydraulic
tank and clean the filter material of the breather in sol-
vent. Replace the fill cap and breather assembly if air
will not flow through it easily.
Replace the hydraulic oil and filter after the first 350
hours of operation. To replace the element, remove
and plug the hose at the fitting near the breather. Re-
move the three nuts and washers that fasten the plate
to the top of the tank. Carefully lift the plate assembly
and filter element while keeping the assembly vertical.
The filter element is held on the bottom of the fitting
tube by a grommet mounted in the top of the element.
Install the replacement element on the fitting tube.
Reinstall the plate assembly onto the top of the tank.
If your truck is equipped with a ground wire, be sure
to reconnect the wire to the plate assembly before
use. Reconnect the hose to the fitting near the
breather. See Figure 10, Figure 11, or Figure 12.

HOW TO CHANGE HYDRAULIC OIL AND

FILTER

WARNING
The hydraulic oil is hot at normal operating tem-
peratures. Be careful when draining the oil.

CAUTION
Protect the hydraulic system from dirt and con-
taminants when servicing the hydraulic system.

Never operate the pump without the proper

amount of oil in the hydraulic system. The opera-
tion of the hydraulic pump with low oil levels will
damage the pump.

Park the lift truck on a level surface. Completely lower

the mast and the forks.

To drain the oil, put the lift truck on a level surface.

Completely lower the mast and forks. Use a container
with a 38 liter (10 gal) capacity near the supply hose 1. NUT 8. NUT
of the hydraulic tank. Turn the key switch to the OFF 2. LOCKWASHER 9. GASKET
position and disconnect the battery. 3. FILLER/BREATHER 10. FILTER
4. SCREW 11. HYDRAULIC TANK
5. LOCKWASHER 12. SIGHT WINDOW
6. FITTING 13. TRIM
7. TANK COVER

Figure 10. Change the Oil Filter (OS030EF)

19
Maintenance Procedures Every 350 Hours or 2 Months 8000 YRM 1472

1. NUT 1. NUT
2. WASHER 2. WASHER
3. FILLER/BREATHER 3. FILLER/BREATHER
4. SCREW 4. SCREW
5. WASHER 5. WASHER
6. FITTING 6. FITTING
7. HYDRAULIC TANK COVER 7. HYDRAULIC TANK COVER
8. NUT 8. NUT
9. GASKET 9. GASKET
10. FILTER ELEMENT 10. FILTER ELEMENT
11. HYDRAULIC TANK 11. HYDRAULIC TANK
12. SIGHT GAUGE 12. SIGHT GAUGE
13. BOLT
14. NUT Figure 12. Change the Oil Filter (FS030BF)
15. THREAD SEAL
16. GROUND WIRE
Figure 11. Change the Oil Filter (OS030BF and
SS030BF)

20
8000 YRM 1472
Raise the front of the lift truck as described in How to
Put a Lift Truck on Blocks. Disconnect the hose from
the tube and drain the oil. Connect the hose to the
tube and tighten the hose clamp. Remove the fill cap
and fill the tank so the oil level is at the center of the
sight gauge. Fill the hydraulic tank with the oil shown
in the Maintenance Schedule. See How to Make
Checks With Key Switch in the OFF Position for the
correct filling procedure.
NOTE: If the filter element slips off the tube during
removal or installation, use the end of the tube to
move the filter element into the correct position to in-
sert the tube in the element.
Check the hydraulic system for leaks and damage or
loose components. Close the hydraulic compartment
door.
CHECK FOR LEAKS IN LIFT SYSTEM
WARNING
Never allow anyone under a raised platform or
forks. DO NOT put any part of your body in or
through either lift mechanism unless all parts of
the mast and carriage are completely lowered and
the key switch is in the OFF position.
Before making any repairs, use chains on the
mast weldments and carriage so they cannot
move. Make sure the moving parts are fastened to
the parts that cannot move.
DO NOT try to find hydraulic leaks by putting your
hand on hydraulic components under pressure.
Hydraulic oil can be injected into the body by the
pressure.
During test procedures for the hydraulic system,
fasten the load to the carriage with chains to pre-
vent it from falling. Keep all personnel away from
the lift truck during the tests.
Maintenance Procedures Every 350 Hours or 2 Months
Check the hydraulic system for internal leaks after ev-
ery 350 hours of operation.
Check Lift Cylinders for Leaks
1. Operate the hydraulic system. Put a capacity load
on the forks and raise and lower the load several
times. Check for leaks.
2. Raise the carriage and load 1 m (3 ft). If the car-
riage slowly lowers when the control valve is in
the neutral position, there are leaks inside the hy-
draulic system. The maximum speed that the
forks can slowly lower when there are internal
leaks is 50 mm (2 in.) per 10 minutes. This maxi-
mum leak rate is specified for an oil temperature
of 30°C (90°F). If the temperature of the hydraulic
oil is 70°C (160°F), the specification increases to
150 mm (6 in.) per 10 minutes.
3. If there are leaks in the hydraulic system, check
the lift cylinders for internal leaks.
4. Completely lower the forks. Install a gate valve at
the base of each main lift cylinder. Raise the load.
Close the gate valve at the base of one main lift
cylinder. Move the Lift/Lower knob to lower the
mast. If the load slowly lowers, the seals in one
main cylinder leak. The cylinder that has the leak
is the cylinder with the closed valve. Open the
gate valve of the first main cylinder and close the
gate valve at the base of the other main cylinder.
Repeat the check for the other main lift cylinder.
5. If the load does not lower with either gate valve
closed, open the gate valve and check the move-
ment again. If the load lowers when the gate
valve is open, check for leaks in the hydraulic
lines and fittings. If no leaks are found, the lower-
ing valve can have a malfunction. Remove the
load from the forks.
6. Completely lower the forks. Remove all gate
valves and connect the hydraulic lines to the cyl-
inders.
21
Maintenance Procedures Every 350 Hours or 2 Months 8000 YRM 1472

ELECTRICAL INSPECTION
Motor Brushes

WARNING
Disconnect the battery before making any checks
on the motors. Personal injury or equipment and
tool damage can occur if the battery is not discon-
nected.

CAUTION
Low battery voltage makes motors use high cur-
rents for a longer time to do the same work. The
high currents can damage motors and contactor
contacts. DO NOT operate the lift truck using a
battery that has a specific gravity of 1.130 or less.

Open the front compartment doors for access to the

motors.
1. LIFT PUMP MOTOR
To check the motor brushes, disconnect the battery
and get access to the motor. Check motor brushes Figure 13. Inspect the Motor Brushes (OS030EF)
using the following procedure:

1. Visually inspect the commutator and brushes ev-

ery 350 hours on the hydraulic and drive motors.
See Figure 13 or Figure 14. Remove the brush
cover. Move the brush spring to remove a brush
from the holder. Pull the brush from the holder.
Make sure the surface of the commutator is good
and the operation of the motor is correct. Replace
brushes before they are worn to the values shown
in Table 3.

1. LIFT PUMP MOTOR

2. COMM END COVER BAND (EE ONLY)
3. DRIVE END COVER BAND (EE ONLY)

Figure 14. Inspect the Motor Brushes (SS030BF,

FS030BF, and OS030BF)

22
8000 YRM 1472
Table 3. Motor Brush Minimum Dimensions
Motor Dimension A
Lift Pump Motor 14 mm (0.55 in.)
FS030BF/OS030BF/
OS030EF/SS030BF
NOTE: Measure brush from armature side to spring
side. Use smallest measurement.
2. Inspect the brush holders for burns or damage.
Make sure the brush holder is fastened tightly to
the mounts. Make sure the brushes will move
freely and smoothly in the brush holders and do
not have wire breaks.
3. Check the brush springs for damage from heat
(color changes) and corrosion. Replace a dam-
aged brush spring.
4. Use dry compressed air under low pressure to re-
move any brush dust.
NOTE: See the section DC Motor Maintenance
0620YRM0294 for additional information for repair of
the commutator and brushes.
CASTER WHEEL
Use multipurpose grease to lubricate the caster
wheels at four lubrication fittings. Inspect caster
wheels for excessive wear and defects, replace if nec-
essary.
MAST
WARNING
To avoid injury or damage, never work under a
raised platform or forks. Lower the platform and
the forks or use chains on the mast weldments
and carriage so they cannot move. When chains
are used, make sure the moving parts are fas-
tened to a part that cannot move.
Make sure all safety labels are installed in the cor-
rect location on the lift truck. Make sure all labels
are not damaged and that they can be read. If nec-
essary, see the Frame section or the Parts Manual
Maintenance Procedures Every 350 Hours or 2 Months
for your lift truck for the correct location of the la-
bels. See the Frame section for the installation
procedures.
1. Inspect the surfaces in the channels where the
load rollers travel. A scraper and solvent can be
used to clean dirt from the mast channels.
CAUTION
Be careful when steam or high-pressure water is
used to clean the mast channels. DO NOT permit
the steam or water to be used on the load rollers,
sheaves, or lift chains. The steam or water will
damage the bearings in the load rollers and
sheaves, and will cause corrosion in the lift
chains.
2. Apply a thin layer of multipurpose grease to the
surfaces in the channels of the inner mast where
the load rollers travel. Apply the grease to both
the roller surfaces and the thrust surfaces in the
mast.
NOTE: The mast and platform load rollers have
sealed bearings that do not need additional lubrica-
tion.
3. Use multipurpose grease to lubricate all sliding
surfaces and the chain sheaves at the top of the
masts.
4. Lubricate the lift chains using the oil specified in
the Maintenance Schedule.
LIFT CHAINS
CAUTION
DO NOT repair a worn lift chain. Replace a worn
lift chain with a new lift chain. Both chains must
be replaced if one lift chain needs replacing.
Lubricate the lift chains using the oil specified in the
Maintenance Schedule.
If a section of chain is 3% longer than a similar sec-
tion of new chain, replace the worn chain.
If a chain scale is available, check the lift chains as
shown in Figure 15. If a chain scale is not available,
measure 20 links of chain. Compare the lengths with
the chart in Figure 15. Replace the chain if the length
of 20 links of the worn section is more than the maxi-
mum wear limit.
23
Maintenance Procedures Every 350 Hours or 2 Months 8000 YRM 1472

NOTE: THE INSTRUCTIONS FOR MEASURING CHAIN WEAR ARE SHOWN ON THE CHAIN WEAR SCALE.

Pitch
Total Length of 20 Links (Pitch) of Wear Limit
New Chain The Maximum Length of 20 Links

12.7 mm (0.5 in.) 254.0 mm (10.0 in.) 261.6 mm (10.3 in.)

15.9 mm (0.6 in.) 317.5 mm (12.5 in.) 327.0 mm (12.9 in.)
19.1 mm (0.8 in.) 381.0 mm (15.0 in.) 392.4 mm (15.5 in.)
25.4 mm (1.0 in.) 508.0 mm (20.0 in.) 523.3 mm (20.6 in.)
31.8 mm (1.5 in.) 635.0 mm (25.0 in.) 654.1 mm (25.8 in.)
44.5 mm (1.8 in.) 889.0 mm (35.0 in.) 915.7 mm (36.1 in.)
50.8 mm (2.0 in.) 1016.0 mm (40.0 in.) 1046.5 mm (41.2 in.)

1. WORN PIN 5. LOOSE LEAVES

2. CRACKS 6. DAMAGED PIN
3. EDGE WEAR 7. CORROSION
4. HOLE WEAR 8. CHAIN WEAR SCALE

Figure 15. Inspect the Lift Chains

24
8000 YRM 1472
ELECTRICAL CABLE SHEAVES
Lubricate the cable sheaves at the top of the mast
and cylinder head using SAE 30 oil.
MASTER DRIVE UNIT
NOTE: The oil used in the master drive unit should
be drained and replaced after the first 350 hour/two
month interval in accordance with the maintenance
schedule. After the initial oil change, the master drive
unit requires only the addition of the recommended oil
to maintain the oil at the proper level.
Maintenance Procedures Every 2000 Hours or Yearly
NOTE: Do these procedures in addition to the 8-hour
and the 350-hour checks.
ELECTRICAL INSPECTION
Contactors
WARNING
Disconnect the battery connector before making
any inspections or repairs. Personal injury or
equipment and tool damage can occur if the bat-
tery is not disconnected.
CAUTION
If the lift truck has been operated using a low bat-
tery or de-energized with the power disconnect
circuit, inspect for welded contacts BEFORE con-
necting a charged battery. The Power Disconnect
circuit will not reset, and lift truck operation can-
not be controlled if the contacts are welded.
Low battery voltage makes motors use high cur-
rents for a longer time to do the same work. The
high currents can damage motors and weld con-
tactor contacts. Never try to repair contactor con-
tacts that are welded. Always replace welded con-
tacts. DO NOT operate the lift truck using a bat-
tery that has a specific gravity of 1.130 or less.
The contact surfaces of the contactor are a silver alloy
over a copper base. In normal operation, the contact
surfaces become a dark color and rough. Cleaning is
not necessary. DO NOT use a file or emery cloth on
the contacts. Replace the contacts when the surface
Maintenance Procedures Every 2000 Hours or Yearly
Drain the oil when it is warm by removing the drain
plug and fill plugs. Use a drain pan under the drain to
keep oil off the floor. Install the drain plug and fill the
unit by adding oil slowly. Allow enough time for the oil
to flow through the bearings to fill the reservoir. The
correct level is at the bottom of the fill plug. Check the
oil level by removing the fill plug. The oil is at the
proper level when it is up to the bottom of the fill plug
hole of the housing. DO NOT fill the master drive unit
with oil above the proper level.
is worn to the base material. Always replace the con-
tacts in sets (two pairs). If necessary, disassemble the
contactor to inspect the contacts.
Open the electrical compartment for access to the
contactors.
MASTER DRIVE UNIT
Traction Motor and Input Pinion Splines
NOTE: The traction motor shaft and MDU input pin-
ion splines should be lubricated every 2000 hours.
To lubricate the traction motor shaft and MDU input
pinion, remove the traction motor from the drive unit.
Wipe the motor shaft splines and the drive unit input
pinion clean. Apply Dow Corning® Molykote G-N
paste (or equivalent)(Yale P/N 580000793) with a
small brush to moderately coat internal MDU splines
and external drive motor shaft splines before reinstal-
ling motor to the drive unit. Refer to Master Drive
Unit 0630YRM1460 for instructions on removing and
installing the traction motor.
WHEELS AND BEARINGS
Check that the drive wheel nuts are tightened to the
value shown in the Maintenance Schedule.
Remove each load wheel and the bearings as descri-
bed in the section How to Replace Load Wheels.
Check each bearing for smooth operation. If the bear-
ing operation is not smooth, replace the bearing. In-
stall the load wheels as described in the section How
to Replace Load Wheels.
25
Maintenance Procedures Every 2000 Hours or Yearly 8000 YRM 1472

HOW TO CHANGE HYDRAULIC OIL AND

FILTER

WARNING
The hydraulic oil is hot at normal operating tem-
peratures. Be careful when draining the oil.

CAUTION
Protect the hydraulic system from dirt and con-
taminants when servicing the hydraulic system.

Never operate the pump without the proper

amount of oil in the hydraulic system. The opera-
tion of the hydraulic pump with low oil levels will
damage the pump.

Park the lift truck on a level surface. Completely lower

the mast and the forks.

To drain the oil, put the lift truck on a level surface.

Completely lower the mast and forks. Use a container
with a 38 liter (10 gal) capacity near the supply hose
of the hydraulic tank. Turn the key switch to the OFF
position and disconnect the battery. 1. NUT
2. LOCKWASHER
Replace the element every 2000 hours or yearly with 3. FILLER/BREATHER
4. SCREW
each oil change. To replace the element, remove and 5. LOCKWASHER
plug the hose at the fitting near the breather. Remove 6. FITTING
the three nuts and washers that fasten the plate to the 7. TANK COVER
top of the tank. Carefully lift the plate assembly and 8. NUT
filter element while keeping the assembly vertical. The 9. GASKET
10. FILTER
filter element is held on the bottom of the fitting tube 11. HYDRAULIC TANK
by a grommet mounted in the top of the element. In- 12. SIGHT WINDOW
stall the replacement element on the fitting tube. Rein- 13. TRIM
stall the plate assembly onto the top of the tank. If
your truck is equipped with a ground wire, be sure to Figure 16. Change the Oil Filter (OS030EF)
reconnect the wire to the plate assembly before use.
Reconnect the hose to the fitting near the breather.
See Figure 16, Figure 17, or Figure 18.

26
8000 YRM 1472 Maintenance Procedures Every 2000 Hours or Yearly

1. NUT 1. NUT
2. WASHER 2. WASHER
3. FILLER/BREATHER 3. FILLER/BREATHER
4. SCREW 4. SCREW
5. WASHER 5. WASHER
6. FITTING 6. FITTING
7. HYDRAULIC TANK COVER 7. HYDRAULIC TANK COVER
8. NUT 8. NUT
9. GASKET 9. GASKET
10. FILTER ELEMENT 10. FILTER ELEMENT
11. HYDRAULIC TANK 11. HYDRAULIC TANK
12. SIGHT GAUGE 12. SIGHT GAUGE
13. BOLT
14. NUT Figure 18. Change the Oil Filter (FS030BF)
15. THREAD SEAL
16. GROUND WIRE
Figure 17. Change the Oil Filter (OS030BF and
SS030BF)

27
Battery Maintenance
Raise the front of the lift truck as described in How to
Put a Lift Truck on Blocks. Disconnect the hose from
the tube and drain the oil. Connect the hose to the
tube and tighten the hose clamp. Remove the fill cap
and fill the tank so the oil level is at the center of the
sight gauge. Fill the hydraulic tank with the oil shown
in the Maintenance Schedule. See How to Make
Checks With Key Switch in the OFF Position for the
correct filling procedure.
NOTE: If the filter element slips off the tube during
removal or installation, use the end of the tube to
move the filter element into the correct position to in-
sert the tube in the element.
Check the hydraulic system for leaks and damage or
loose components. Close the hydraulic compartment
door.
Battery Maintenance
HOW TO CHARGE BATTERY
WARNING
The acid in the electrolyte can cause injury. If
electrolyte is spilled, use water to flush the area.
Make the acid neutral with a solution of sodium
bicarbonate (baking soda) and water. Acid in the
eyes must be immediately flushed with water con-
tinuously for fifteen minutes, then seek medical
attention.
Batteries generate explosive fumes. Keep the
vents in the caps clean. Keep sparks or open
flames away from the battery area. DO NOT make
a spark from the battery connections. Disconnect
the battery when doing maintenance.
If the lift truck has been operated using a low bat-
tery or de-energized using the power disconnect
switch (see "Battery Disconnect Switch" in the
Operating Manual), inspect for welded contacts
BEFORE connecting a charged battery. The cir-
cuit will not reset and lift truck operation cannot
be controlled if the contacts are welded. To check
the contacts, see Contactors in this manual.
28
8000 YRM 1472
INSPECTION OF PERSONAL FALL
PROTECTION SYSTEM
WARNING
The Personal Fall Protection is specially made to
lessen the shock of a fall. Do not substitute other
types of ropes or straps.
1. A trained technician must inspect for any damage
which may affect the form, fit or function of the
Personal Fall Protection System.
2. Inspect the lanyard for wear, deformation, exces-
sive elongation, cuts or damage. Inspect the clips
for cracks, broken hardware, corrosion, and
proper operation. Replace as necessary.
3. Inspect the full body harness or body belt for fray-
ing, cracks, cuts, deformation or wear. Inspect
any hardware for cracks, broken hardware, corro-
sion and proper operation. Replace as necessary.
CAUTION
Never connect the battery charger directly to the
lift truck. Battery charger should only be attached
to battery assembly. Failure to do so may result in
damage to the electrical circuit. Always make sure
the charger amperage is correct for your model
lift truck.
Correct use of the hydrometer (Figure 19) and proper
operation of the battery charger is important. Operate
the battery charger according to the instructions of the
charger manufacturer. Never let the battery discharge
below the minimum value given by the battery manu-
facturer. A fully charged battery will have a specific
gravity of 1.265 to 1.310 at 25°C (77°F). Never charge
a battery at a rate that will raise the electrolyte tem-
perature above 49°C (120°F). Never permit a battery
to stay discharged for long periods.
8000 YRM 1472 Battery Maintenance

NOTE: Many customers have battery chargers that

can follow a program to automatically charge a bat-
tery according to recommendations of the battery
manufacturer. Use the recommendations of the bat-
tery manufacturer for charging the battery.

HOW TO CHANGE THE BATTERY

General

WARNING
Batteries are heavy and can cause an injury. Use
care to avoid injury. DO NOT put hands, arms,
feet, or legs between the battery and a solid ob-
ject.

To prevent personal injury and unexpected bat-

tery movement, the battery must be level when it
Specific Electrolyte Correction Correct is moving. Make sure the battery stand is on a
Gravity Temp. Points Value level surface and is aligned and adjusted as de-
Reading scribed in the following procedure.
1.210 31°C (88°F) +0.003 1.213
The previous warning must be observed when chang-
1.210 27°C (81°F) +0.001 1.211
ing the battery.
1.210 25°C (77°F) 0.000 1.210
1.210 18°C (64°F) −0.004 1.206 Battery, Remove
±0.001 for each 2°C from the 25°C base value. 1. Move the key switch to the OFF position. Use the
Figure 19. How to Check Specific Gravity battery disconnect to disconnect the battery.

2. Move to a position in front of the battery compart-

1. NORMAL CHARGE: This charge is normally given
to a battery that is discharged from normal operation.
Many customers charge the battery at regular inter-
vals that depend on use. This procedure will keep the
battery correctly charged if the battery is not dis-
charged below the limit. Always use a hydrometer to
check the battery if the battery is charged at regular
intervals. Frequent charging of a battery that has a
2/3 or more charge can decrease the life of the bat-
tery.
2. EQUALIZING CHARGE: This charge is at a low
rate and balances the charge in all of the cells. The
equalizing charge is normally given approximately
once a month. It is a charge at a slow rate for 3 to 6
hours in addition to the regular charging cycle. DO
NOT give an equalizing charge more than once a
week. The most accurate specific gravity measure-
ment of specific gravity for a charged battery will be
after an equalizing charge. If the difference in specific
gravity is more than 0.020 between cells of a battery
after an equalizing charge, a cell may have a malfunc-
tion. Consult your battery dealer.
ment panel on the side for the battery stand.
3. Align the battery stand with the battery so the end
of the stand is against the roller frame for the bat-
tery. Adjust the capscrew legs of the battery stand
so the tops of the rollers are the same height as
the bottom of the battery and the rollers are level.
4. Install the battery puller on the end of the stand at
the center. See Figure 20. Release the ratchet
lock and attach the hook to the lifting hole of the
battery. DO NOT permit the hook to make contact
with cell connectors. Make sure the battery cables
are not damaged during battery removal. Stand
on the base of the battery puller, release the
ratchet, and operate the crank to pull the battery
onto the battery stand.
5. If the battery is lifted, use a spreader bar and
crane to lift the battery from the battery stand.

29
Battery Maintenance
NOTE: ILLUSTRATION ON LEFT SHOWS INSTALLATION; ILLUSTRATION ON RIGHT SHOWS REMOVAL.
1. BATTERY COMPARTMENT
2. LATCH FOR COMPARTMENT PANEL
3. BATTERY STAND
4. ROLLERS
Figure 20. How to Change the Battery
Battery, Install
WARNING
Make sure the capacity of the crane and spreader
bar is greater than the weight of the battery. The
weight of the battery is normally shown on the
battery case. The maximum battery weight is
shown on the lift truck nameplate. The spreader
bar must NOT be made of metal, or it must have
insulated straps. Batteries are heavy. Use care to
avoid injury.
If the lift truck was operated using a low battery or
de-energized using the power disconnect switch,
inspect for welded contacts BEFORE connecting
a charged battery. The circuit will not reset, and
lift truck operation cannot be controlled if the con-
tacts are welded. To check the contacts, see Con-
tacts in this manual. Make sure that the battery
voltage and weight of the replacement battery are
correct as shown on the nameplate.
30
8000 YRM 1472
5. BATTERY PULLER
6. RATCHET LOCK LEVER
7. BATTERY
CAUTION
The replacement battery must fit the battery com-
partment.
Before connecting the battery, make sure the key
switch is in the OFF position and the brake is on.
1. Make sure the battery is the correct size and
weight for the lift truck. The correct battery is
specified in Table 4. Make sure the battery has
clearance for installation and the battery connec-
tor can be connected after installation. Make sure
the battery compartment has the correct spacers
for the battery you are installing. The spacers
must not let the battery move more than
13.0 mm (0.5 in.) in any direction. The spacers
must keep the battery as far from the mast as
possible. Have authorized personnel replace or
adjust the battery spacers for that battery. See
your Hyster lift truck dealer for the correct
spacers. DO NOT damage the battery cables dur-
ing installation.
8000 YRM 1472 Wheels and Tires

2. Install the battery puller on the lift truck frame at
the center of the battery compartment on the side
opposite the battery stand. See Figure 20. Re-
lease the ratchet lock, pass the hook through the
battery compartment, and attach the hook to the
battery lifting hole. DO NOT permit the hook to
make contact with the cell connectors. Stand on
the base of the battery puller and operate the
crank to pull the battery off the stand into the bat-
tery compartment. Make sure the foot switch is re-
leased and the key switch is in the OFF position
before connecting the battery.

Table 4. Battery Specifications

Model Volts Compartment Size Battery Size* Weight

Length × Width Minimum/Maximum
Length Width Minimum Maximum
OS/SS/ 24/36 990.00 × 371.00 mm 880.00 to N/A to (OS030BF) (OS030BF)
FS030BF (38.90 × 14.60 in.) 987.00 mm 368.00 mm 726 kg 862 kg
(34.60 to (N/A to (1600 lb) (1900 lb)
38.90 in.) 14.50 in.) (FS/SS030BF) (FS/SS030BF)
680 kg 907 kg
(1500 lb) (2000 lb)
OS030EF 24 911.00 × 343.00 mm 791.00 to N/A to 408 kg 544 kg
(35.8.00 × 13.50 in.) 902.00 mm 330.00 mm (900 lb) (1200 lb)
(31.10 to (N/A to
35.50 in.) 13.00 in.)
Compartment width is measured across the width of the lift truck. The battery's length is the installed length as
measured from side to side across lift truck. Battery width is the installed width as measured from front to back
of the lift truck.
*Maximum height for OS/SS/FS030BF batteries is 787.0 mm (30.80 in.). Maximum height for OS030EF batteries
is 590.00 mm (23.25 in.).
N/A = Minimum battery width is not available.

Wheels and Tires

HOW TO CHANGE DRIVE AND STEER
TIRES
CAUTION
If the wheels have been removed and installed,
check all wheel nuts after 2 to 5 hours of opera-
tion. Tighten the nuts in a cross pattern to the cor-
rect torque value shown in the Maintenance
Schedule table. When the nuts stay tight for 8
hours, the interval for checking the torque can be
extended to 2000 hours.
To change the drive tire, the wheel must be pressed
out of the rim. The correct tools, equipment, and
press ring must be used for each size wheel. A press
that has a capacity of approximately
36,000 kg (80,000 lb) is also required to press the
wheel out of the rim. This is not a job that an operator
should attempt. Have the tires changed by authorized
personnel that have the proper tools, equipment, and
experience. Similar tires can be installed as optional
equipment. DO NOT mix types of tires or brands of
tires on the lift truck. See Figure 21.

Raise the front of the lift truck as described in How to

Put a Lift Truck on Blocks. Remove the wheel nuts
that fasten the drive/steer wheel to the hub. Slide the
wheel out from under the lift truck. Use the reverse
procedure to install the wheel. Tighten the wheel nuts
to 135 N•m (100 lbf ft) after installation.

31
Wheels and Tires 8000 YRM 1472

HOW TO REPLACE LOAD WHEELS

CAUTION
For correct operation of the wire guidance sys-
tem, all load wheels must always be replaced at
the same time.

Put the base arms up on blocks as described in How

to Put a Lift Truck on Blocks. To replace the load
wheels on the OS030BF and OS030EF, remove the
axle and axle nut from load wheel brackets. Remove
the load wheel. Remove the axle sleeve and bearing
from the load wheel. The load wheel brackets are
1. PRESS RING 3. NEW TIRE held in the base arms by the load wheels. Install the
2. OLD TIRE 4. WHEEL HUB bearings and axle sleeve into the replacement load
wheel. Install the load wheel, axle, and the axle nut
Figure 21. Position Tire on Wheel into the load wheel brackets. Torque the axle nut to
68 N•m (50 lbf ft). See Figure 22. To replace the load
wheels on the SS030BF and FS030BF, remove the
pin securing the axle shaft in the base arm and re-
move the axle shaft. Remove the load wheel and re-
cover the washers from each side. Install the bearings
into the replacement load wheel. Install the load
wheel and washers into the base arm and secure with
the axle shaft. Install the pin into the base arm and
axle shaft. See Figure 23.

32
8000 YRM 1472 Wheels and Tires

1. BASE ARM 4. LOAD WHEEL

2. WASHERS 5. PIN
3. BEARING 6. AXLE SHAFT
1. BASE ARM
2. LOAD WHEEL BRACKET Figure 23. How to Replace Load Wheels
3. AXLE (FS030BF and SS030BF)
4. AXLE SLEEVE
5. BEARING
6. LOAD WHEEL
7. AXLE NUT

Figure 22. How to Replace Load Wheels

(OS030BF and OS030EF)

33
 NOTES

34