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.
i
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.
1
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.
2
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.
5
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