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MSW020-025E (A895) SERVICE MANUAL CONTENTS SECTION

PART NUMBER

YRM NUMBER

REV DATE

FRAME............................................................................................................................ DC MOTOR MAINTENANCE.......................................................................................... MASTER DRIVE UNIT.................................................................................................... STEERING SYSTEM...................................................................................................... BRAKE SYSTEM............................................................................................................ WALKIE HIGH LIFT HYDRAULIC SYSTEM.................................................................. ELECTRICAL SYSTEM.................................................................................................. ZAPI CONTROLLERS.................................................................................................... INDUSTRIAL BATTERY................................................................................................. MAST DESCRIPTION..................................................................................................... MAST REPAIRS............................................................................................................. LIFT CYLINDERS........................................................................................................... METRIC AND INCH (SAE) FASTENERS....................................................................... PERIODIC MAINTENANCE............................................................................................ CAPACITIES AND SPECIFICATIONS........................................................................... DIAGRAMS.....................................................................................................................

524190262 524158039 524154891 524154892 524154893 524175625 524154896 524185045 524158040 524175626 524175627 524175628 524150797 524175629 524175630 524175631

0100 YRM 1069 0620 YRM 0294 0630 YRM 1003 1600 YRM 1004 1800 YRM 1005 2000 YRM 1044 2200 YRM 1007 2200 YRM 1064 2240 YRM 0001 4000 YRM 1045 4000 YRM 1046 4000 YRM 1047 8000 YRM 0231 8000 YRM 1048 8000 YRM 1049 8000 YRM 1050

05/03 03/08 03/08 03/08 03/08 04/08 01/14 05/14 09/14 05/03 07/10 05/03 10/13 02/07 10/06 02/07

Service information for Cummins diesel engines can be ordered through the Hyster Literature Distribution Center. PART NO. 524167348 (09/14)


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 condition that can cause immediate death or injury!

CAUTION Indicates a condition that can cause property damage!


Capacities and Specifications

Table of Contents

TABLE OF CONTENTS Lift and Hydraulic System Specifications............................................................................................................. Hydraulic Oils ...................................................................................................................................................... Master Drive Unit Specifications.......................................................................................................................... Gear Oils ............................................................................................................................................................. Grease................................................................................................................................................................. Tire Specifications ............................................................................................................................................... Torque Specifications .......................................................................................................................................... Master Drive Unit ............................................................................................................................................ Brake ............................................................................................................................................................... Steering........................................................................................................................................................... Mast ................................................................................................................................................................ Frame .............................................................................................................................................................. Travel Speeds ...................................................................................................................................................... Truck Weight........................................................................................................................................................ Battery Specifications..........................................................................................................................................

1 1 2 2 3 3 3 3 3 3 4 4 4 4 5

This section is for the following models: MSW020/025-E [A895]

Š2006 Yale Materials Handling Corp.

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8000 YRM 1049

Hydraulic Oils

Lift and Hydraulic System Specifications Specification

MSW020-E

MSW025-E

2.2 kW

2.2 kW

200 bar (2900 psi)

200 bar (2900 psi)

With Load

28

28

Without Load

50

50

With Load

60

60

Without Load

56

56

Motor Power Hydraulic Relief Pressure Lifting Speed

1

Lowering Speed 2

Lift Cycle Limit

Not to Exceed One (1) Lift Every Two (2) Minutes

Allowable Drift With Load

25 mm/Min (1 in/Min)

Hydraulic Oil Standard

ISO VG 46 Anti-Wear (HCE-140)

CS/Freezer

Exxon Univis® HVI 26 (Synthetic)

Hydraulic Reservoir Capacity 1 2

Feet per Minute (+10%, Feet per Minute (±10%)

3.6 liter (0.95 gal)

5%)

Hydraulic Oils Operating Condition

Standard

CS/Freezer

For All Hydraulically-Actuated Equipment Specification

ISO VG 46 Antiwear (HCE-140)

Exxon Univis® HVI 26

Type

Conventional

Synthetic

Temperature Range Pour Point Maximum

32 to

120 C (89.6 to 15 C (5.0 F)

184.0 F)

0 to

120 C (32.0 to

184.0 F)

60 C ( 76.0 F)

Field Personnel Note: The product listed above is the approved source that meets or exceeds YALE specifications. The use of products other than that listed above is unauthorized.

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Gear Oils

8000 YRM 1049

Master Drive Unit Specifications Gear Ratio

Capacity

42.2:1

189 ml (6.4 oz)

Oil Specification Standard

CS/Freezer

80W-90 Gear Oil (API GL-5)

80W-90 Gear Oil (API GL-5)

Gear Oils Operating Condition

Standard/CS/Freezer

SAE Grade

80W-90

Type

Multipurpose EP

Base Oil

Conventional Petroleum

MIL-Specification No.

MIL-L-2105C

API Service Classification

GL-5

Anticipated Ambient Temperature

26 to +38 C ( 15 to +100 F) Most YALE lift truck operations will fall within this temperature range. Approved Sources

Chevron

Chevron Universal Gear Lube 80W/90

Exxon

Exxon Gear Oil GX 80W/90

Mobil

Mobilube HD 80W/90

Pennzoil

Pennzoil MP 4092

Phillips 66

Philube SMP Gear Oil 80W/90

Solene Lub. Inc.

Solene Gear Oil #905

Sun

Sunfleet GL-5 Gear Lube 80W/90

Union 76

Unocal MP Gear Lube LS 80W/90

Field Personnel Note: The products listed above are the approved sources that meet or exceed YALE specifications. The use of products other than that listed above is unauthorized.

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8000 YRM 1049

Torque Specifications

Grease Fittings and Wheel Bearings Application

Standard

CS/Freezer

Approved Vendor

Mobilgrease® 28

Mobilgrease® 28

Oil

Synthetic

Synthetic

Thickener

Clay

Clay

Grade NGLI

1.5

1.5

Dropping Pt.

310 C (590 F)

310 C (590 F)

Field Personnel Note: The product listed above is the approved source that meets or exceeds YALE specifications. The use of products other than that listed above is unauthorized.

Tire Specifications

a b

Lift Truck Model

Capacity

MSW020-E

907 kg (2000 lb)

MSW025-E

1134 kg (2500 lb)

Drive Tire 9 × 4 in. Molded Rubber a 9 × 5 in. Press-on Rubber b 9 × 4 in. Molded Poly 9 × 5 in. Press-on Poly 9 × 5 in. Press-on Siped Poly

Load Wheel 102 × 70 mm (4.0 × 2.75 in.) 102 × 70 mm (4.0 × 2.75 in.)

Standard for MSW020-E Standard for MSW025-E

Torque Specifications MASTER DRIVE UNIT Fill Plug 40 N•m (30 lbf ft) Drive Tire Wheel Capscrew 115 N•m (85 lbf ft)

Gear Case Cover Capscrews 23 N•m (17 lbf ft) Pivot Spindle Mounting Capscrews 23 N•m (17 lbf ft)

BRAKE

Traction Motor Gear Retaining Nut 26 N•m (19 lbf ft)

Installation Screws (3 each) 2.8 N•m (25 lbf in)

Traction Motor Mounting Capscrew 10 N•m (7 lbf ft)

STEERING

Axle Shaft Gear Retaining Nut 175 N•m (129 lbf ft) Drive Unit Pivot Spindle Nut To Seat Bearings torque to: 54 N•m (40 lbf ft) Back off and re-torque to: 34 N•m (25 lbf ft)

Steer Handle to Control Handle Bracket (2 each) 27 N•m (20 lbf ft) Butterfly Throttle Control to Handle (2 each) 1 N•m (9 lbf in) Gas Spring Mounting Studs (2 each) 27 N•m (20 lbf ft)

3


Truck Weight

8000 YRM 1049

Control Arm Support Bracket Pivot Pins (2 each) 142 ±7 N•m (105 ±5 lbf ft)

Wear Strip Capscrews 10 N•m (7 lbf ft)

MAST

FRAME

Lift Cylinder Gland 375 N•m (277 lbf ft)

Straddle Arm Mounting Bolts 300 N•m (221 lbf ft)

Lower Mast Installation Capscrews (2 each) 298.28 N•m (220 lbf ft)

Travel Speeds Travel Speeds (MPH), ±10% Mode 1

Truck Capacity

Mode 2

Mode 3

Optional Creep Mode

Empty

Loaded

Empty

Loaded

Empty

Loaded

Empty

2000 lb

2.1

2.0

2.6

2.4

3.2

2.7

0.9

2500 lb

2.1

2.0

2.6

2.4

3.2

2.7

0.9

Truck Weight Approximate Truck Weight (83 inch OAH, Standard 48 inch Load Backrest, and 1.5×4.0×42 inch Forks)

4

MSW020-E

With Standard Battery Pack

1021 kg (2250 lb)

MSW025-E

Without Battery

907 kg (2000 lb)


8000 YRM 1049

Battery Specifications

Battery Specifications

Figure 1. Battery Compartment Dimensions Battery and Battery Compartment Dimensions Battery

Battery Compartment Dimensions Model

MSW020-E

1

Length (X)

Length (X) mm (in.)

Width (Y) mm (in.)

Height

720 (28.3)

205 (8)

720 (28.3)

230 (9)

Width (Y)

Amperage

Weight

Min 1 Max Min 1 mm (in.) mm (in.) mm (in.)

Max mm (in.)

Max kwh (amp hr)

Min kg (lb)

Max kg (lb)

Open

640 (25.2) 714 (28.1)

143 (5.6)

200 (7.8)

11.9 (510)

141 (310)

170 (375)

Open

640 (25.2) 714 (28.1)

168 (6.6)

224 (8.8)

11.9 (510)

159 (350)

259 (570)

Minimum battery dimensions allowed with standard battery spacer group.

NOTE: 24 Volt DC battery only. Covered batteries required. Battery connector type is 175 Amp, Red (Gray is optional). Cable lead position B. 20-Inch cable length. Maximum cable gauge of 1/0.

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YALE A895 MSW025E LIFT TRUCK Service Repair Manual  
YALE A895 MSW025E LIFT TRUCK Service Repair Manual  
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