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Yale Forklift B895 (MSW025_030-F) Service Manual – PDF DOWNLOAD
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Yale Forklift B895 (MSW025_030-F) Service Manual – PDF DOWNLOAD
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Description
Yale Forklift B895 (MSW025_030-F) Service Manual – PDF DOWNLOAD
FILE DETAILS:
Yale Forklift B895 (MSW025_030-F) Service Manual – PDF DOWNLOAD
Language : English
Pages : 538
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Yale Forklift B895 (MSW025_030-F) Service Manual – PDF DOWNLOAD
General 5
Threaded Fasteners 5
Nomenclature, Threads 5
Strength Identification 6
Cotter (Split) Pins 7
Fastener Torque Tables 12
Conversion Table 14
toc 21
Master Drive Unit 21
Safety Precautions Maintenance and Repair 22
General 25
Description 25
Special Precautions 25
Master Drive Unit Repair 27
Remove 27
Disassemble 29
Repair 30
Assemble 30
Install 30
Troubleshooting 31
General 39
Special Precautions 39
Control Handle Head 40
Control Handle 40
Remove 40
Install 41
Gas Spring 43
Discharging the Gas Spring 43
Troubleshooting 44
toc 47
Brakes 47
Safety Precautions Maintenance and Repair 48
General 51
Description 51
Special Precautions 52
Brake Assembly Repair 53
Brake Override 53
Remove 54
Repair 56
Install 57
Troubleshooting 58
General 65
Description of Operation 67
Special Precautions 69
Moving a Disabled Lift Truck 71
Electrical System Checks 71
Safety Precautions 72
Repairs 73
Controller, Replace 73
Remove 73
Install 76
Contactor Coil, Check 76
Contactor, Replace 77
Remove 77
Install 77
Key Switch Removal and Installation 77
Remove 77
Install 77
Battery Indicator/Hourmeter Display 78
Remove 78
Install 78
Fuses 79
MPB040-E 79
MPW045/050-E
79
MSW020/025-E
79
MSW025/030-F
79
Control Handle Arm Proximity Switch
80
Repair 80
Check and Adjust 80
Remove 80
Install 81
Control Handle 82
Disassemble 82
Control Handle Card (Old Style) 82
Control Handle Card (New Style) 83
Configure 84
Calibrate 85
Assemble 87
Switches (ON/OFF and Proportional) 89
Remove 89
Install 89
Traction Motor 89
Disassemble 90
Assemble 92
Lift Pump Motor 92
Repair (MSW020/025-E and MSW025/030-F) 92
Lift Link Proximity Sensor (MPW050-E) 94
Check 94
Repair 94
Remove 94
Test 94
Install 95
Adjust 95
Battery Charger (Moran®) 95
Description 96
Operation 96
Charging 96
Equalize 96
Signals 96
Protections 96
Troubleshooting 96
Battery Charger (Accusense by DPI®) 100
Description 100
Operation 100
LED Display 100
Charging 101
Charger Mode/Battery Type Selection (DPI Gen II Models) 102
Changing Mode Setting (DPI Gen II Models) 102
Charger Mode/Battery Type Selection (DPI Gen III Models) 103
Changing Mode Setting (DPI Accusense Gen III Models with Jumper Ports) 104
Accusense Gen III with Dip Switches 104
Changing Mode Setting 106
Troubleshooting (DPI Chargers) 106
General 106
Error Modes 107
Battery Pack Troubleshooting 108
Battery Charger (Accusense® 20A) 109
Description 109
Operation 109
LED Display 109
Charging 110
Charger Mode/Battery Type Selection (Accusense 20A) 111
Changing Mode Setting (Accusense 20A) 114
Troubleshooting (Accusense 20A Chargers) 114
General 114
Error Modes 115
Battery Pack Troubleshooting 117
Troubleshooting 118
General 125
Brush and Commutator Inspection 126
Hydraulic Pump Motor and Traction Motor 126
Steering Pump Motor 129
Normal Commutator Surface 129
Commutator Problems 129
Brush Replacement 134
Stoning the Commutator 137
Motors Repair 138
Disassemble 139
Traction Motor and Hydraulic Pump Motor 139
Steering Pump Motor 140
Assemble 144
Traction Motor and Hydraulic Pump Motor 144
Steering Pump Motor 146
Brush Alignment, Traction and Hydraulic Motors 148
Tests for Damaged Field and Armature 149
Test for an Open Circuit in One Armature Winding 149
Test for Short Circuit in One Armature Winding 149
Test for Short Circuit to Armature Shaft 150
Test for Open Circuit in Field Coil 150
Test for Short Circuit in Field Coil 151
Test for Short Circuit Between Field and Motor Case 151
Brush Holder Test 151
Troubleshooting 152
General 163
Battery Type 163
Lead-Acid Batteries 163
Lithium-Ion Batteries 164
Specific Gravity 164
Chemical Reaction in a Cell 164
Electrical Terms 166
Battery Selection 167
Battery Voltage 168
Battery as a Counterweight 168
Battery Ratings 168
Kilowatt-Hours 168
Battery Maintenance 169
Safety Procedures 169
Maintenance Records 169
New Battery 169
Cleaning Battery 170
Adding Water to Battery 172
Hydrometer 172
Battery Temperature 173
Charging Battery 174
Types of Battery Charges 175
Methods of Charging 176
Troubleshooting Charger 177
Knowing When Battery Is Fully Charged 177
Where to Charge Batteries 177
Equipment Needed 177
Battery Connectors 178
Battery Care 178
Troubleshooting 180
General 189
Battery Type 189
Lead-Acid Batteries 189
Lithium-Ion Batteries 190
Specific Gravity 190
Chemical Reaction in a Cell 190
Electrical Terms 192
Battery Selection 192
Battery Voltage 193
Battery as a Counterweight 194
Battery Ratings 194
Kilowatt-Hours 194
Battery Maintenance 194
Safety Procedures 194
Maintenance Records 195
New Battery 195
Cleaning Battery 195
Adding Water to Battery 197
Hydrometer 198
Battery Temperature 199
Charging Battery 200
Types of Battery Charges 200
Methods of Charging 202
Troubleshooting Charger 202
Knowing When Battery Is Fully Charged 203
Where to Charge Batteries 203
Equipment Needed 203
Battery Connectors 204
Battery Care 204
Troubleshooting 206
General 215
Mast Weldments 217
Carriages 218
Two-Stage Mast 220
Description 221
Operation 226
Three-Stage Mast 227
Description 227
Operation 230
General 239
Safety Procedures When Working Near Mast 239
Load Backrest Extension, Carriage, Load Rollers, Side Rollers, and Forks 240
Load Backrest Extension, Remove and Install 241
Carriage Assembly, Remove and Install 241
Carriage Load Rollers, Remove and Install 244
Side Rollers, Disassemble and Assemble 244
Fork, Replace 245
Hook-Type Forks 245
Remove 245
Install 245
Forks Check 245
Two-Stage Mast Assembly 248
Remove 248
Clean and Inspect 253
Lift Cylinders, Remove and Install Dual-Lift Cylinders 254
Lift Cylinder, Remove and Install Single Main-Lift Cylinders 255
Remove 255
Install 256
Inner Mast Assembly, Remove and Install 257
Hoses, Replace 257
Hose and Cable Sheaves, Replace 257
Two-Stage Lift Chains 259
Remove and Install 259
Clean and Inspect 259
Two-Stage Chain Sheave, Remove and Install 260
Load Rollers and Wear Plugs, Remove and Install 260
Two-Stage Mast Assembly, Install 261
Three-Stage Mast Assembly 262
Three-Stage Mast Assembly, Remove 262
Clean and Inspect 263
Free-Lift Cylinder, Remove and Install 266
Main Cylinders (Standard), Remove and Install 267
Inner and Intermediate Mast Assemblies, Remove and Install 269
Hoses, Replace 269
Hose and Cable Sheaves, Replace 271
Free-Lift Hose Sheave 271
Carriage Sheaves 271
Three-Stage Lift Chains, Remove and Install 272
General 272
Free-Lift Chains 272
Main-Lift Chains 272
Three-Stage Chain Sheaves, Disassemble and Assemble 273
Free-Lift Chain Sheaves 273
Main-Lift Chain Sheaves 273
Load Rollers and Wear Plugs, Remove and Install 273
Three-Stage Mast Assemble, Install 274
Mast Operation Check 275
Hydraulic System Leaks Check 275
Lift Chains Check 276
General 276
Clean and Inspect 276
Lubrication 277
Mast Adjustments 277
General 278
Adjust Wear Plugs – Mast 278
Adjust Free-Lift Chain (Three-Stage Only) 280
Adjust Main-Lift Chains 280
Two-Stage 280
Three-Stage 282
Adjust Wear Strips 282
Carriage Adjustments 283
Adjust Wear Plug – Carriage 283
Adjust Side Rollers – Carriage 283
Adjust Thrust Rollers – Carriage 284
Troubleshooting 285
General 293
Description 293
Lowering Control Valve 294
Main Cylinder Repair 295
Disassemble 296
Assemble 297
Free-Lift Cylinder Repair 298
Disassemble 298
Assemble 298
Troubleshooting 300
toc 303
Walkie High Lift Hydraulic System 303
Safety Precautions Maintenance and Repair 304
General 307
Description of Operation 307
Hydraulic Oil 308
Clean 308
Sound Level 308
Special Precautions 308
Control Valve 309
Hydraulic Reservoir 310
Description 310
Manual Lowering 310
Lift Pump and Motor 312
General 312
Remove Lift Pump and Motor Assembly 313
Disassemble 313
Remove Reservoir 313
Remove Pump Motor 315
Disassemble Pump 315
Assemble 319
Assemble Pump 319
Install Pump Motor 319
Install Reservoir to Pump 319
Install Lift Pump and Motor Assembly 319
Valve Repair 320
Proportional Valve (Lowering) 320
Remove 320
Install 320
Relief Valve and Check Valve 320
Remove 320
Install 321
Relief Valve Adjustment 321
Bleed Hydraulic System 322
Troubleshooting 323
Hydraulic Schematic 325
tables 303
Table 1 Reservoir Capacities 310
Table 2 Reservoir Capacities 319
General 333
Description 334
ZAPI™ Transistor Motor Controller 334
Principles of Operation 334
Controller Safety 335
Controller Adjustments 335
Modes of Operation 336
User-Selectable Operating Modes 336
Programming 337
Custom Performance Mode 337
Controller Parameters 337
Setting Drive Modes 337
Tester Menu 339
Set Option Menu 339
ZAPI™ Handset 340
Alarm Code Diagnostics 343
Alarm Code Diagnostic Procedure 344
Troubleshooting 346
Auxiliary Hydraulics (MSW030/040-E, MRW020/030-E, MCW025/030/040-E) 370
Control Card Functional Test 375
Traction Motor Test 376
ZAPI™ PC Interface 378
Connecting PC to ZAPI™ Controller 378
File Menu 382
Open File 382
TX From File 384
Save File 386
Print Settings 388
Exit 389
Connection Menu 390
Function Menu 390
Parameter 390
Memory Menu 395
Set Options 396
Tester 398
Data Logger 400
Alarm Logbook 403
Alarms 405
Programming Tilt and Sideshift on the ZAPI Controller (Laptop) 405
Repair 406
Remove 406
Brass Stud Replacement 406
Remove 406
Install 406
Install 406
Repair 407
Sideshift Setup With Auxiliary (MRW020/030-E) 407
toc 411
Frame 411
Safety Precautions Maintenance and Repair 412
General 415
Description 415
Features 416
Frame Repair 416
Base Arms 416
Remove 417
Install 418
Adjust 418
Painting Instructions 418
Label Replacement 418
Battery Compartment 420
tables 411
Table 1 Base Arm Width 416
General 427
How to Move a Disabled Lift Truck 427
How to Tow a Lift Truck 427
How to Put The Lift Truck on Blocks 429
How to Raise the Drive/Steer Tire 429
How to Raise the Load Wheels 431
Attachments 431
Special Precautions 431
Discharging the Capacitor 431
Safety Procedures When Working Near Mast 432
Maintenance Schedule 433
Maintenance Procedures Every 8 Hours or Daily 438
Checks Before Operation 438
How to Make Checks With Key Switch OFF 438
Safety Labels 438
Battery 439
Brake 439
Tires and Wheels 439
Mast, Forks, and Lift Chains 440
Control Handle 442
Hydraulic System 442
How to Make Checks With Key Switch ON 443
Check for Leaks in Lift System 443
Control Buttons 443
Direction/Speed Control and Switches 443
Gauges, Horn, Fuses 444
Maintenance Procedures Every 350 Hours or Every 2 Months 444
Fittings Lubrication 444
Other Lubrication 444
Base Arm Capscrews 444
Battery 445
Brake 445
Lift Chain Adjustments 445
Drive Wheel 447
Hydraulic System 447
Master Drive Unit 447
Traction and Pump Motor Brushes 447
Contactor 449
Maintenance Procedures Every 2000 Hours or Yearly 449
Load Wheels 449
Forks Check 449
Hydraulic Oil Change 451
How to Change Drive Unit Oil 452
Welding Repairs 453
General Repairs 453
Load Wheels(MSW025-30-F) 453
Remove 453
Install 454
Lift Cylinder Leak Test 454
Battery Maintenance 454
How to Charge the Battery 455
Normal Charge 455
Equalizing Charge 456
Industrial Battery Charging 456
Battery Pack Charging 456
How to Change the Battery 456
Standard Battery Spacer Adjustment 456
Changing the Battery With an Overhead Crane 457
Remove 457
Install 457
Changing Batteries on Lift Trucks With Battery Power Pack GP 458
Remove 458
Install 459
Lubrication Specifications 467
Hydraulic System 467
Master Drive Unit Specifications 467
Tires and Wheels 468
Torque Specifications 468
Frame 468
Master Drive Unit 468
Brake 468
Steering 469
Hydraulic 469
Mast 469
Truck Weights 469
Travel Speeds 469
Battery Specifications 470
General 501
AccuSense® Q-Series Charger 501
Charger Mode/Battery Type Selection 502
Mode Setting Check 503
Convenience Port 504
Multi-Stage Charging 505
LED Display, Multi-Stage Charge 507
Cell, Battery, and Battery Pack Voltage 508
Voltages 508
Troubleshooting 509
Charger Troubleshooting 509
Error Code Description 509
Diagnostics and Troubleshooting 511
Output Connector Circuit 512
Vehicle Lockout Control Option 513
General 523
Threaded Fasteners 523
Nomenclature, Threads 523
Strength Identification 524
Cotter (Split) Pins 525
Fastener Torque Tables 530
Conversion Table 532
S.V 06/24
