Yale Forklift A895 (MSW020_025E) Service Manual – PDF DOWNLOAD

Description

Yale Forklift A895 (MSW020_025E) Service Manual – PDF DOWNLOAD

FILE DETAILS:

Yale Forklift A895 (MSW020_025E) Service Manual – PDF DOWNLOAD

Language : English
Pages : 458
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Yale Forklift A895 (MSW020_025E) Service Manual – PDF DOWNLOAD

524150797-8000YRM0231-(02-2023)-US-EN 1
General 7
Threaded Fasteners 7
Nomenclature, Threads 7
Strength Identification 8
Cotter (Split) Pins 9
Fastener Torque Tables 14
Conversion Table 16
524150797-8000YRM0231-(03-2020)-US-EN 23
General 27
Threaded Fasteners 27
Nomenclature, Threads 27
Strength Identification 28
Cotter (Split) Pins 29
Fastener Torque Tables 34
Conversion Table 36
524154891-0630YRM1003-(03-2008)-US-EN 43
toc 43
Master Drive Unit 43
Safety Precautions Maintenance and Repair 44
General 47
Description 47
Special Precautions 47
Master Drive Unit Repair 49
Remove 49
Disassemble 51
Repair 52
Assemble 52
Install 52
Troubleshooting 53
524154892-1600YRM1004-(10-2015)-US-EN 57
General 61
Special Precautions 61
Control Handle Head 62
Control Handle 62
Remove 62
Install 63
Gas Spring 65
Discharging the Gas Spring 65
Troubleshooting 66
524154893-1800YRM1005-(03-2008)-US-EN 69
toc 69
Brakes 69
Safety Precautions Maintenance and Repair 70
General 73
Description 73
Special Precautions 74
Brake Assembly Repair 75
Brake Override 75
Remove 76
Repair 78
Install 79
Troubleshooting 80
524154896-2200YRM1007-(10-2016)-US-EN 83
General 87
Description of Operation 89
Special Precautions 91
Moving a Disabled Lift Truck 93
Electrical System Checks 93
Safety Precautions 94
Repairs 95
Controller, Replace 95
Remove 95
Install 98
Contactor Coil, Check 98
Contactor, Replace 99
Remove 99
Install 99
Key Switch Removal and Installation 99
Remove 99
Install 99
Battery Indicator/Hourmeter Display 100
Remove 100
Install 100
Fuses 101
MPB040-E 101

MPW045/050-E
101

MSW020/025-E
101

MSW025/030-F
101

Control Handle Arm Proximity Switch
102
Repair 102
Check and Adjust 102
Remove 102
Install 103
Control Handle 104
Disassemble 104
Control Handle Card (Old Style) 104
Control Handle Card (New Style) 105
Configure 106
Calibrate 107
Assemble 109
Switches (ON/OFF and Proportional) 111
Remove 111
Install 111
Traction Motor 111
Disassemble 112
Assemble 114
Lift Pump Motor 114
Repair (MSW020/025-E and MSW025/030-F) 114
Lift Link Proximity Sensor (MPW050-E) 116
Check 116
Repair 116
Remove 116
Test 116
Install 117
Adjust 117
Battery Charger (Moran®) 117
Description 118
Operation 118
Charging 118
Equalize 118
Signals 118
Protections 118
Troubleshooting 118
Battery Charger (Accusense by DPI®) 122
Description 122
Operation 122
LED Display 122
Charging 123
Charger Mode/Battery Type Selection (DPI Gen II Models) 124
Changing Mode Setting (DPI Gen II Models) 124
Charger Mode/Battery Type Selection (DPI Gen III Models) 125
Changing Mode Setting (DPI Accusense Gen III Models with Jumper Ports) 126
Accusense Gen III with Dip Switches 126
Changing Mode Setting 128
Troubleshooting (DPI Chargers) 128
General 128
Error Modes 129
Battery Pack Troubleshooting 130
Battery Charger (Accusense® 20A) 131
Description 131
Operation 131
LED Display 131
Charging 132
Charger Mode/Battery Type Selection (Accusense 20A) 133
Changing Mode Setting (Accusense 20A) 136
Troubleshooting (Accusense 20A Chargers) 136
General 136
Error Modes 137
Battery Pack Troubleshooting 139
Troubleshooting 140
524158039-0620YRM0294-(09-2016)-US-EN 143
General 147
Brush and Commutator Inspection 148
Hydraulic Pump Motor and Traction Motor 148
Steering Pump Motor 151
Normal Commutator Surface 151
Commutator Problems 151
Brush Replacement 156
Stoning the Commutator 159
Motors Repair 160
Disassemble 161
Traction Motor and Hydraulic Pump Motor 161
Steering Pump Motor 162
Assemble 166
Traction Motor and Hydraulic Pump Motor 166
Steering Pump Motor 168
Brush Alignment, Traction and Hydraulic Motors 170
Tests for Damaged Field and Armature 171
Test for an Open Circuit in One Armature Winding 171
Test for Short Circuit in One Armature Winding 171
Test for Short Circuit to Armature Shaft 172
Test for Open Circuit in Field Coil 172
Test for Short Circuit in Field Coil 173
Test for Short Circuit Between Field and Motor Case 173
Brush Holder Test 173
Troubleshooting 174
524158040-2240YRM0001-(01-2023)-US-EN 179
General 185
Battery Type 185
Lead-Acid Batteries 185
Lithium-Ion Batteries 186
Specific Gravity 186
Chemical Reaction in a Cell 186
Electrical Terms 188
Battery Selection 189
Battery Voltage 190
Battery as a Counterweight 190
Battery Ratings 190
Kilowatt-Hours 190
Battery Maintenance 191
Safety Procedures 191
Maintenance Records 191
New Battery 191
Cleaning Battery 192
Adding Water to Battery 194
Hydrometer 194
Battery Temperature 195
Charging Battery 196
Types of Battery Charges 197
Methods of Charging 198
Troubleshooting Charger 199
Knowing When Battery Is Fully Charged 199
Where to Charge Batteries 199
Equipment Needed 199
Battery Connectors 200
Battery Care 200
Troubleshooting 202
524158040-2240YRM0001-(03-2020)-US-EN 207
General 211
Battery Type 211
Lead-Acid Batteries 211
Lithium-Ion Batteries 212
Specific Gravity 212
Chemical Reaction in a Cell 212
Electrical Terms 214
Battery Selection 214
Battery Voltage 215
Battery as a Counterweight 216
Battery Ratings 216
Kilowatt-Hours 216
Battery Maintenance 216
Safety Procedures 216
Maintenance Records 217
New Battery 217
Cleaning Battery 217
Adding Water to Battery 219
Hydrometer 220
Battery Temperature 221
Charging Battery 222
Types of Battery Charges 222
Methods of Charging 224
Troubleshooting Charger 224
Knowing When Battery Is Fully Charged 225
Where to Charge Batteries 225
Equipment Needed 225
Battery Connectors 226
Battery Care 226
Troubleshooting 228
524175625-2000YRM1044-(04-2008)-US-EN 233
toc 233
Walkie High Lift Hydraulic System 233
Safety Precautions Maintenance and Repair 234
General 237
Description of Operation 237
Hydraulic Oil 238
Clean 238
Sound Level 238
Special Precautions 238
Control Valve 239
Hydraulic Reservoir 240
Description 240
Manual Lowering 240
Lift Pump and Motor 242
General 242
Remove Lift Pump and Motor Assembly 243
Disassemble 243
Remove Reservoir 243
Remove Pump Motor 245
Disassemble Pump 245
Assemble 249
Assemble Pump 249
Install Pump Motor 249
Install Reservoir to Pump 249
Install Lift Pump and Motor Assembly 249
Valve Repair 250
Proportional Valve (Lowering) 250
Remove 250
Install 250
Relief Valve and Check Valve 250
Remove 250
Install 251
Relief Valve Adjustment 251
Bleed Hydraulic System 252
Troubleshooting 253
Hydraulic Schematic 255
tables 233
Table 1 Reservoir Capacities 240
Table 2 Reservoir Capacities 249
524175626-4000YRM1045-(05-2003)-US-EN 259
toc 259
Mast Description 259
Safety Precautions Maintenance and Repair 260
General 263
Mast Weldments 263
Carriage 264
Mast Assembly 265
Mast Mounts 265
524175627-4000YRM1046-(05-2003)-US-EN 271
toc 271
Mast Repairs 271
Safety Precautions Maintenance and Repair 272
General 275
Safety Procedures When Working Near Mast 275
Mast Repair 276
Remove 276
Disassemble 277
Assemble 279
Install 281
Carriage Repair 282
Remove 282
Disassemble 283
Assemble 283
Install 283
Fork Repair 284
Check 284
Remove 285
Install 285
Lift Chain Adjustment 286
Inspect 286
Adjust 286
Wear Strips Adjustment 287
524175628-4000YRM1047-(05-2003)-US-EN 291
toc 291
Lift Cylinders 291
Safety Precautions Maintenance and Repair 292
General 295
Safety Procedures When Working Near Mast 295
Safety Chain the Mast 295
Blocking the Mast 296
Description 296
Lift Cylinders 296
Flow Control Valve 296
Lift System Check 297
Leak Test 297
Lift Cylinder Repair 298
Remove 298
Disassemble 299
Repair 299
Assemble 301
Install 301
Troubleshooting 302
524175629-8000YRM1048-(02-2007)-US-EN 305
toc 305
Periodic Maintenance 305
Safety Precautions Maintenance and Repair 306
General 309
How to Move a Disabled Lift Truck 309
How to Tow a Lift Truck 309
How to Put The Lift Truck on Blocks 311
How to Raise the Drive/Steer Tire 311
How to Raise the Load Wheels 311
Special Precautions 312
Discharging the Capacitor 312
Maintenance Schedule 313
Safety Procedures When Working Near Mast 316
Maintenance Procedures Every 8 Hours or Daily 318
Checks Before Operation 318
How to Make Checks With Key Switch OFF 318
Safety Labels 318
Battery 318
Brake 319
Tires and Wheels 319
Mast, Forks, and Lift Chains 319
Control Handle 322
Hydraulic System 322
How to Make Checks With Key Switch ON 322
Check for Leaks in Lift System 322
Control Buttons 322
Direction/Speed Control and Switches 323
Gauges, Horn, Fuses 323
Maintenance Procedures Every 350 Hours or Every 2 Months 324
Fittings Lubrication 324
Other Lubrication 324
Base Arm Capscrews 324
Battery 324
Brake 324
Lift Chain Adjustments 324
Drive Wheel 326
Hydraulic System 326
Master Drive Unit 326
Traction and Pump Motor Brushes 327
Contactor 329
Maintenance Procedures Every 2000 Hours or Yearly 329
Load Wheels 329
Hydraulic Oil Change 329
How to Change Drive Unit Oil 330
Welding Repairs 331
General Repairs 331
Load Wheels 331
Remove 331
Install 332
Lift Cylinder Leak Test 332
Battery Maintenance 333
How to Charge the Battery 333
Normal Charge 333
Equalizing Charge 334
Industrial Battery Charging 334
Battery Pack Charging 334
Battery Spacer Adjustment 334
How to Change the Battery 336
Changing the Battery With an Overhead Crane 336
Remove 336
Install 336
tables 305
Table 1 Maintenance Schedule 314
Table 2 Fuse Ratings 323
524175630-8000YRM1049-(10-2006)-US-EN 341
toc 341
Capacities and Specifications 341
Safety Precautions Maintenance and Repair 342
Lift and Hydraulic System Specifications 345
Hydraulic Oils 345
Master Drive Unit Specifications 346
Gear Oils 346
Grease 347
Tire Specifications 347
Torque Specifications 347
Master Drive Unit 347
Brake 347
Steering 347
Mast 348
Frame 348
Travel Speeds 348
Truck Weight 348
Battery Specifications 349
524175631-8000YRM1050-(02-2007)-US-EN 353
toc 353
Diagrams 353
Safety Precautions Maintenance and Repair 354
524185045-2200YRM1064-(08-2016)-US-EN 365
General 369
Description 370
ZAPI™ Transistor Motor Controller 370
Principles of Operation 370
Controller Safety 371
Controller Adjustments 371
Modes of Operation 372
User-Selectable Operating Modes 372
Programming 373
Custom Performance Mode 373
Controller Parameters 373
Setting Drive Modes 373
Tester Menu 375
Set Option Menu 375
ZAPI™ Handset 376
Alarm Code Diagnostics 379
Alarm Code Diagnostic Procedure 380
Troubleshooting 382
Auxiliary Hydraulics (MSW030/040-E, MRW020/030-E, MCW025/030/040-E) 406
Control Card Functional Test 411
Traction Motor Test 412
ZAPI™ PC Interface 414
Connecting PC to ZAPI™ Controller 414
File Menu 418
Open File 418
TX From File 420
Save File 422
Print Settings 424
Exit 425
Connection Menu 426
Function Menu 426
Parameter 426
Memory Menu 431
Set Options 432
Tester 434
Data Logger 436
Alarm Logbook 439
Alarms 441
Programming Tilt and Sideshift on the ZAPI Controller (Laptop) 441
Repair 442
Remove 442
Brass Stud Replacement 442
Remove 442
Install 442
Install 442
Repair 443
Sideshift Setup With Auxiliary (MRW020/030-E) 443
524190262-0100YRM1069-(05-2003)-US-EN 447
toc 447
Frame 447
Safety Precautions Maintenance and Repair 448
General 451
Description 451
Features 451
Frame Repair 452
Base Arms 452
Base Arms 452
Remove 452
Install 453
Adjust 454
Painting Instructions 454
Label Replacement 454
Battery Compartment 455
tables 447
Table 1 Base Arm Width 452

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