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Place new battery in correct location on battery tray.

See

Figure 23

Secure battery to battery tray7 with battery strap

clamp. See

Figure 23

Connect battery cables.

Install side plates on each side of battery compart-

ment, making sure brackets and bumpers hold plates in
place. See

Figure 23

Close top plate.

Install knob in hole on top plate and turn clockwise to

tighten. See

Figure 23

Connect battery connector and turn lift truck power

Make sure the weight of the replacement battery is within

the maximum and minimum weights shown on the name-
plate.

Figure 21. Changing the Battery

Maintenance

Summary of Contents for MSW020-E

Page 1: ...e High Lift Trucks MSW020 E MSW025 E A895 MSW025 F MSW030 F B895 MCW025 E MCW030 E MCW040 E C819 D819 MSW030 E MSW040 E C820 D820 MRW020 E MRW030 E C821 D821 PART NO 524150809 7 18 DO NOT REMOVE THIS...

Page 2: ...R SERIAL NUMBER COMPOSITION SPECIAL EQUIPMENT OR ATTACHMENTS Yale Material Handling Corporation 2018 All Rights Reserved YALE and VERACITOR are Registered Trademarks of Hyster Yale Group Inc CSS PREMI...

Page 3: ...the equipment safely Various laws and regulations require the employer to train lift truck operators These laws and regulations include Occupational Safety and Health Act OSHA USA Canada Material Hand...

Page 4: ...ational Safety Council Guide for Users of Industrial Lift Trucks Yale Part No 504295733 describes lift truck safety good mainte nance practices and training programs and is available from your dealer...

Page 5: ...CK 42 Driving and Direction Changes 42 Steering Turning 43 LOAD HANDLING 44 Lifting Lowering and Tilting 45 Manual Lowering 46 Removing a Load From a Stack 48 Putting a Load on a Stack 49 TRAVELING 51...

Page 6: ...OVING A DISABLED LIFT TRUCK 87 PUTTING THE LIFT TRUCK ON BLOCKS 88 How to Raise Drive Steer Tire 89 How to Raise Load Wheels MSW020 025 030 040 E MRW020 030 E and MSW025 030 F 92 How to Raise Load Whe...

Page 7: ...Do not ride truck unless it is designated as a rider type truck by manufacturer Do not move truck if anyone is between truck and sta tionary object Keep hands within handle guards and feet clear of tr...

Page 8: ...te truck with forks trailing whenever possible Always face direction of travel WHEN WALKING control truck with one hand using steer handle Walk to the side of the steer handle When truck is operated f...

Page 9: ...off power set brakes remove key and dis connect battery Disengage coast control Block wheels if truck is parked on an incline TAKE CARE WHEN CHARGING Charge battery only in designated area When chargi...

Page 10: ...hods of stopping are available One method of stopping and direction changing is controlled plugging electrical braking Controlled plugging is reversing the speed direction control while traveling caus...

Page 11: ...equipment it will be lis ted Make sure the Nameplate data is complete and fully understood before operating the lift truck The lift truck serial number code is on the Nameplate The serial number code...

Page 12: ...Figure 2 Nameplate Warning Labels and Decals Model Description 10...

Page 13: ...RNING LABEL 5 OPERATING MANUAL 6 YALE BLACK DECAL 7 WARNING LABEL 8 BATTERY DISCHARGE NOTICE LABEL 9 MOVING MAST LABEL 10 MANUAL LOWERING LABEL Major Components of Lift Truck Figure 3 Figure 4 Figure...

Page 14: ...HORN 5 OPERATOR MANUAL 6 BATTERY INDICATOR OPTIONAL 7 BATTERY CONNECTOR 8 KEY SWITCH 9 FORKS 10 CARRIAGE 11 MAST 12 BATTERY COMPARTMENT 13 LOAD WHEEL 14 BASE ARM 15 DRIVE STEER TIRE Figure 3 Major Co...

Page 15: ...ERATOR MANUAL 6 BATTERY INDICATOR OPTIONAL 7 BATTERY CONNECTOR 8 KEY SWITCH 9 FORKS 10 CARRIAGE 11 MAST 12 BATTERY COMPARTMENT 13 LOAD WHEEL 14 BASE ARM 15 DRIVE STEER TIRE 16 REACH MECHANISM Figure 4...

Page 16: ...NS 4 HORN 5 OPERATOR MANUAL 6 BATTERY INDICATOR OPTIONAL 7 BATTERY CONNECTOR 8 KEY SWITCH 9 FORKS 10 CARRIAGE 11 MAST 12 BATTERY COMPARTMENT 13 LOAD WHEEL 14 DRIVE STEER TIRE Figure 5 Major Components...

Page 17: ...HORN 5 OPERATOR MANUAL 6 BATTERY INDICATOR OPTIONAL 7 BATTERY CONNECTOR 8 KEY SWITCH 9 FORKS 10 CARRIAGE 11 MAST 12 BATTERY COMPARTMENT 13 LOAD WHEEL 14 BASE ARM 15 DRIVE STEER TIRE Figure 6 Major Co...

Page 18: ...UAL 6 BATTERY INDICATOR OPTIONAL 7 BATTERY CONNECTOR 8 KEY SWITCH 9 FORKS 10 CARRIAGE 11 MAST 12 BATTERY COMPARTMENT 13 LOAD WHEELS 14 BASE ARMS 15 DRIVE TIRE 16 DRIVE UNIT COMPARTMENT 17 OPERATOR GUA...

Page 19: ...s and Controls WARNING If any of the instruments or controls do not operate as described in Table 1 report the problem immediately DO NOT operate the vehicle until the problem is correc ted Model Desc...

Page 20: ...position and engage the brake Arrows on the butterfly type knobs speed direction control indicate the direction of travel of the lift truck Lift lower traction reverse and horn are controlled by separ...

Page 21: ...handle assembly has the following controls 1 Traction Reverse button 2 Horn button 3 Direction and speed control 4 Slow speed button Optional 5 Proportional Lower button 6 Proportional Lift button 7 L...

Page 22: ...action Reverse button 2 Horn button 3 Direction and speed control 4 Slow speed button Optional 5 Proportional Lower button 6 Proportional Lift button 7 Lift button Optional Sideshift Right 8 Lower but...

Page 23: ...eed Direction Control The speed direction control is for selecting forward or reverse movement and the travel speed of the lift truck The control has a spring which will return it to the OFF position...

Page 24: ...ction motor will not move the lift truck in the direction of the control handle until the control is reset To reset move the speed direction control to the OFF position or move the handle to the BRAKE...

Page 25: ...d Button The Walkie High Lift Counterbalance Truck MCW and High Lift Reach Truck MRW have button controls for Tilt To activate the Tilt control on the Walkie High Lift Counterbalance Truck press the T...

Page 26: ...ruck press the Tilt Back Button to tilt the forks up Release the button to stop the fork motion To activate the Tilt control on the Walkie High Lift Reach Truck first press and hold the grey Shift but...

Page 27: ...ure 6 and Figure 7 Continued Item No Item Function 1 Extend Button The Walkie High Lift Reach Trucks MRW have buttons to control the Reach func tion To Extend reach forward the forks and carriage push...

Page 28: ...Controls See Figure 3 Figure 4 Figure 5 Figure 6 and Figure 7 Continued Item No Item Function 1 Retract Button To Retract return the forks and carriage push the Retract Button To stop release the butt...

Page 29: ...ift Left The Walkie High Lift Trucks have an optional Sideshift function This function repla ces the Lift and Lower control buttons To shift the forks left press the Left Sideshift Button Release the...

Page 30: ...pushed by the operator Release the but ton to stop raising The lift button is a timed function If the lift button is depressed after the maximum lift height is attained the lift function will stop If...

Page 31: ...ector CAUTION Make sure the voltage of the battery is the same as specified on the name plate The connector halves must be connected for operation To disconnect the battery separate the halves of the...

Page 32: ...Function 8 Key Switch The key switch has two positions OFF and ON Traction or hydraulic functions will NOT operate with the key switch in the OFF position NOTE Always raise the control handle to the...

Page 33: ...ive or lift mode Periodic maintenance recommendations are based on these operating hours The battery indicator has a LED display of state of charge As the battery s state of charge decreases successiv...

Page 34: ...d DOES NOT INDICATE A FAULT CODE NOTE Fault codes may be generated in response to extreme operating conditions such as rapid stops potholes or a severely discharged battery therefore disabling the tru...

Page 35: ...edium Top Speed 90 of full speed Neutral Braking medium level Mode 3 Performance without Neutral Braking Acceleration maximum Top Speed 100 of full speed Neutral Braking minimum To select the performa...

Page 36: ...cator Red Indicator Yellow Indicator Green Indicator NOTE If any of the RED indicators are flashing during the charging cycle contact maintenance 12 Battery Charger MSW025 E and MSW025 030 F Later Mod...

Page 37: ...sconnect the battery connector before charging the battery Connect AC cord to a 120 volt AC outlet This will automatically charge the batteries The battery charger has status indicators Power On Conne...

Page 38: ...and the load is also a factor This basic principle is used to pick up a load The ability of the lift truck to handle a load is discussed in terms of center of gravity and stabil ity Stability and Cent...

Page 39: ...ide the CG must stay within the area of the lift truck represented by a triangle drawn between the load wheels and the pivot of the steering axle A LOAD WHEEL AXLE B STEERING AXLE PIVOT C CG TRUCK WIL...

Page 40: ...nter of the lift truck is measured from the front face of the forks or the load face of an attachment to the center of gravity of the load The location of the center of gravity in the vertical directi...

Page 41: ...to no more than 1 2 inch Condition of forks carriage chains and mast Leaks from the hydraulic system Condition of wheels and tires WARNING Report damage or faulty operation immediately Do not operate...

Page 42: ...ing every operator must receive addi tional training even if they have a license to drive an auto mobile The following discussion lists basic procedures applicable to lift truck operation 1 Authorized...

Page 43: ...ith the platform in place to make sure the mast functions properly Apply the parking brake DO NOT travel with people in the platform The opera tor must remain at the controls Watch for overhead obstru...

Page 44: ...d away from the upright position This will energize the electrical system The brakes are automatically applied when the steering handle is in the extreme upper or lower position 4 Rotate the speed dir...

Page 45: ...these conditions WARNING Do not move the Reach or Tilt control when the lift truck is traveling The attachment can be damaged if it is extended when the lift truck is traveling WARNING Failure to obse...

Page 46: ...rection of travel When traveling facing the load place both hands on the steering handle Keep your arm straight If the lift truck moves away from you your stiff arm will force the handle down into a b...

Page 47: ...ng and Tilting WARNING The lift truck can tip over forward when the load is raised Forward tipping is even more likely when extending the forks tilting forward braking when trav eling forward or accel...

Page 48: ...ure Verify that there are no obstructions beneath the lift mechanism or load If the mast does not lower when the manual lowering valve is activated deactivate the valve immediately and determine the c...

Page 49: ...manual lowering process is complete by slowly turning the screw clockwise until it stops Tighten the man ual override screw to 36 in lb 0 7 0 Figure 9 Single Function Manual Lowering Control Figure 10...

Page 50: ...the forks under the load The forks must support at least two thirds 2 3 of the length of the load Make sure that the load is centered between the forks Make sure that the forks do not extend past the...

Page 51: ...put on the floor tilt the load forward to a vertical position and lower the load Tilt the load forward to permit smooth removal of the forks Carefully move the lift truck backward to remove the forks...

Page 52: ...truck is equipped with tilt function Lower the forks just enough to remove them from under the load Do not lower the forks so that they will drag on the surface under the load WARNING Safe neat stack...

Page 53: ...Traveling 1 Keep hands and fingers inside the control handle guard to avoid injury from passing obstructions Keep feet clear of the lift truck when walking with the lift truck Travel slowly when turn...

Page 54: ...ift truck is reduced This is also true when the lift truck is not carrying a load 4 Travel with the load trailing and look in the direction of travel If the lift truck must travel in a direction where...

Page 55: ...nd the front of the load If the forks extend beyond the load the operator can hit an object or lift another load WARNING Serious accidents can be caused by the mast hitting pipes and beams near the ce...

Page 56: ...ned to move the lift truck away from the edge of the dock the rear will swing toward the edge of the dock This action can cause the lift truck to fall off the dock 5 Make sure that the railroad car br...

Page 57: ...a condition that can cause damage and injury When parking the lift truck do the following operations 1 Bring the lift truck to a stop Fully lower the forks Fully retract the forks Tilt the forks forw...

Page 58: ...Maintenance Schedule Figure 11 Maintenance Points MSW030 040 E Figure 12 Maintenance Points MSW020 025 E Maintenance Schedule 56...

Page 59: ...Figure 13 Maintenance Points MRW020 030 E Figure 14 Maintenance Points MCS025 030 040 E Maintenance Schedule 57...

Page 60: ...Figure 15 Maintenance Points MSW025 030 F Maintenance Schedule 58...

Page 61: ...evel See Specifications 3 Brake X Check Operation Hold 10 grade w rated load 4 Tires and Wheels Drive and Load X Check Damage Replace as Necessary 5 Mast X X Check Condition Channel Wear Surfaces L Cl...

Page 62: ...eration Smooth No Binding Pivot Shaft L L 1 Lube Fitting Lubricate Friction Points Multipurpose Grease5 Engine Oil 10 Hydraulic System X 8 5 liter 9 0 qt 6 8 No Leaks Check Level X C 11 5 liter 12 1 q...

Page 63: ...uses X Check Operation 14 Articulating Chain Anchors6 7 L 2 Lube Fittings Multipurpose Grease5 15 Chain Hose and Wire Sheaves L Check Condition Clean and Lubricate Engine Oil 16 Reach Frame Thrust Rol...

Page 64: ...ighten if Required 190 to 217 N m 140 to 160 lbf ft 20 Load Wheel Bearings2 L6 8 L7 2 Lube Fittings6 8 Clean and Repack7 Multipurpose Grease5 Multipurpose Grease5 21 Master Drive Unit Oil Level MRW MC...

Page 65: ...h week 5 Multipurpose Grease with 2 4 Molybdenum Disulfide for normal operations 6 MSW020 025 030 040 E only 7 MCS025 030 040 E only 8 MRS020 030 E only 9 Replace after the first 200 hours and check r...

Page 66: ...ler to help users who do their own maintenance Put the lift truck on a level surface Lower the forks discon nect the battery and remove the drive unit cover Check for any leaks and conditions that are...

Page 67: ...em Operation of the hydraulic pump without oil will damage it Forks The identification of a fork is determined by how it is con nected to the lift truck These lift trucks have hook type forks Adjustme...

Page 68: ...s Replace damaged forks Forks are to be replaced only in sets and not individually 1 Inspect forks for cracks and wear Check that fork tips are aligned as shown in Figure 16 Check that bottom of fork...

Page 69: ...replace it DANGER OF BREAKING Furthermore a 10 reduc tion in fork blade thickness results in 20 reductions in operating capacity Fork Tip Alignment Length of Forks 3 Dimension 914 mm 36 in 27 mm 1 10...

Page 70: ...t Chains WARNING Do not try to correct fork tip alignment by bending the forks or adding shims Never repair damaged forks by heating or welding Forks are made of special steel using special procedures...

Page 71: ...Periodic Maintenance section for specific instructions 7 Inspect the lift chains for cracks or broken links and pins See Figure 18 8 Inspect the chain anchors and pins for cracks and dam age 9 Make s...

Page 72: ...trol handle stating DO NOT OPERATE Remove the key and disconnect the battery WARNING Do the following checks in an area that is clear of other personnel or equipment 1 Check the operation of the key s...

Page 73: ...ction motor should not accelerate the lift truck toward the control handle Full direction control may be re established by rotating the speed direction control to the OFF position or by moving the con...

Page 74: ...the acid neutral with a solution of soda and water 1 pound of baking or commercial soda to 1 gallon of water Acid in the eyes must be flushed with water Have a doctor check the eyes WARNING Batteries...

Page 75: ...te can cause injury Use water to flush the area and make the acid neutral with a solu tion of soda and water 1 pound of baking or commer cial soda to 1 gallon of water Acid in the eyes must be flushed...

Page 76: ...rk This high current flow can damage the motor contactors and the battery Do not operate the lift truck with a battery that has a corrected specific gravity of less than the minimum value specified by...

Page 77: ...ns Specific Gravity Reading Electrolyte Temperature Correction Points Correct Value 1 210 31 C 87 F 0 003 1 213 1 210 27 C 80 F 0 001 1 211 1 210 25 C 77 F 0 000 1 210 1 210 18 C 64 F 0 004 1 206 0 00...

Page 78: ...g the battery make sure the battery is cleaned and painted When a replace ment battery is installed make sure the battery fits the bat tery compartment Use spacers to prevent the battery from moving m...

Page 79: ...battery compart ment making sure brackets and bumpers hold plates in place See Figure 23 e Close top plate f Install knob in hole on top plate and turn clockwise to tighten See Figure 23 g Connect bat...

Page 80: ...Legend for Figure 21 1 SPREADER BAR 2 STRAPS THAT ARE NOT METAL 3 BATTERY Figure 22 Battery Compartment Dimensions Maintenance 78...

Page 81: ...Figure 23 Remove Install Battery From Battery Power Pack Maintenance 79...

Page 82: ...Legend for Figure 23 1 TOP PLATE 2 KNOB 3 SIDE PLATE 4 BUMPER 5 BRACKET 6 BRACKET STRAP CLAMP 7 BATTERY CABLES 8 BATTERY TRAY 9 BATTERY Maintenance 80...

Page 83: ...48 25 5 218 8 6 592 23 3 181 400 268 590 6 0 255 MSW040 E 24 838 33 0 343 13 5 673 26 5 330 13 0 592 23 3 227 500 374 825 8 7 375 MSW040 E 24 838 33 0 343 13 5 663 26 1 325 12 8 592 23 3 249 550 392 8...

Page 84: ...13 5 673 26 5 330 13 0 592 23 3 227 500 374 825 8 7 375 MCW030 E 24 838 33 0 343 13 5 663 26 1 325 12 8 592 23 3 249 550 392 865 9 9 425 MCW030 E 24 838 33 0 343 13 5 785 30 9 330 13 0 592 23 3 272 6...

Page 85: ...5 785 30 9 330 13 0 592 23 3 272 600 448 987 10 5 450 MRW020 E 24 838 33 0 343 13 5 785 30 9 330 13 0 592 23 3 283 625 469 1035 11 9 510 MRW030 E 24 838 33 0 343 13 5 673 26 5 330 13 0 592 23 3 227 50...

Page 86: ...8 217 478 140 310 4 0 158 MSW025 E 24 720 28 3 230 9 0 642 25 3 162 6 4 592 23 3 185 410 287 633 3 5 150 MSW025 E 24 720 28 3 230 9 0 642 25 3 162 6 4 592 23 3 192 425 297 655 3 9 170 MSW025 E 24 720...

Page 87: ...k with 25 Amp Charger 4 4 195 693 27 3 191 7 5 671 26 4 170 375 Industrial 12 75 5 4 4 195 643 25 3 163 6 4 592 23 3 186 410 12 85 5 3 5 150 643 25 3 163 6 4 592 23 3 193 425 12 100 5 3 9 170 643 25 3...

Page 88: ...GP 20 Amp Charger 3 9 170 660 25 9 198 7 8 611 24 0 122 270 Industrial 12 75 5 3 5 150 643 25 3 163 6 4 592 23 3 186 410 12 85 5 3 9 170 643 25 3 163 6 4 592 23 3 193 425 12 100 5 4 6 200 643 25 3 16...

Page 89: ...vel slowly WARNING Make sure no one except the driver is near the lift trucks during towing Both the tow truck and the disa bled truck can cause a personal injury during towing WARNING To avoid person...

Page 90: ...e keep a tag on the control handle stating DO NOT OPERATE Remove the key Putting the Lift Truck on Blocks WARNING Do not put the lift truck on blocks if the surface is not solid even and level Make su...

Page 91: ...ck has the correct capacity rat ing The capacity must equal at least two thirds 2 3 the weight of the lift truck including the battery See the name plate 3 Raise the lift truck only enough to suspend...

Page 92: ...A TOP VIEW B LEFT VIEW 1 DRIVE END 2 FORK END 3 STRAP Figure 24 Lifting Points Maintenance 90...

Page 93: ...Figure 25 Putting the Lift Truck on Blocks MSW MRW Shown Maintenance 91...

Page 94: ...meplate 3 To raise the fork end of the lift truck hook a lift strap through each load wheel opening in the top of each fork and lift together See Figure 24 Raise the outriggers only enough to suspend...

Page 95: ...ions shown in Figure 26 a On drive end of lift truck wrap the strap behind the bumper and inside left hand and right hand cowl b At the center of the lift truck wrap the strap around each side of the...

Page 96: ...A TOP VIEW B LEFT VIEW 1 STRAP 2 ANCHOR POINT Figure 26 Lift Truck Tie Downs Maintenance 94...

Page 97: ...Spacer 7 18 5 18 11 17 8 16 1 16 7 14 2 13 9 09 9 08 3 08...

Page 98: ...e High Lift Trucks MSW020 E MSW025 E A895 MSW025 F MSW030 F B895 MCW025 E MCW030 E MCW040 E C819 D819 MSW030 E MSW040 E C820 D820 MRW020 E MRW030 E C821 D821 PART NO 524150809 7 18 DO NOT REMOVE THIS...

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