This document provides a summary of service manual contents for MSW020-025E (A895) models. It includes: - Sections and part numbers for frame, DC motor maintenance, master drive unit, steering system, brake system, and more. - Specifications for lift and hydraulic systems, master drive unit, tires, torques, speeds, weights and batteries. - Tables listing hydraulic oils, gear oils, grease, and other specifications. - Safety precautions and notes for maintenance and repair.

1. MSW020-025E (A895)
SERVICE MANUAL CONTENTS
SECTION
PART
NUMBER
YRM
NUMBER
REV
DATE
FRAME............................................................................................................................ 524190262 0100 YRM 1069 05/03
DC MOTOR MAINTENANCE.......................................................................................... 524158039 0620 YRM 0294 03/08
MASTER DRIVE UNIT.................................................................................................... 524154891 0630 YRM 1003 03/08
STEERING SYSTEM...................................................................................................... 524154892 1600 YRM 1004 03/08
BRAKE SYSTEM............................................................................................................ 524154893 1800 YRM 1005 03/08
WALKIE HIGH LIFT HYDRAULIC SYSTEM.................................................................. 524175625 2000 YRM 1044 04/08
ELECTRICAL SYSTEM.................................................................................................. 524154896 2200 YRM 1007 01/14
ZAPI CONTROLLERS.................................................................................................... 524185045 2200 YRM 1064 05/14
INDUSTRIAL BATTERY................................................................................................. 524158040 2240 YRM 0001 09/14
MAST DESCRIPTION..................................................................................................... 524175626 4000 YRM 1045 05/03
MAST REPAIRS............................................................................................................. 524175627 4000 YRM 1046 07/10
LIFT CYLINDERS........................................................................................................... 524175628 4000 YRM 1047 05/03
METRIC AND INCH (SAE) FASTENERS....................................................................... 524150797 8000 YRM 0231 10/13
PERIODIC MAINTENANCE............................................................................................ 524175629 8000 YRM 1048 02/07
CAPACITIES AND SPECIFICATIONS........................................................................... 524175630 8000 YRM 1049 10/06
DIAGRAMS..................................................................................................................... 524175631 8000 YRM 1050 02/07
Service information for Cummins diesel engines can be ordered through the Hyster Literature Distribution Center.
PART NO. 524167348 (09/14)

2. SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fas-
tened, 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!

3. Capacities and Specifications Table of Contents
TABLE OF CONTENTS
Lift and Hydraulic System Specifications............................................................................................................. 1
Hydraulic Oils ...................................................................................................................................................... 1
Master Drive Unit Specifications.......................................................................................................................... 2
Gear Oils ............................................................................................................................................................. 2
Grease................................................................................................................................................................. 3
Tire Specifications ............................................................................................................................................... 3
Torque Specifications .......................................................................................................................................... 3
Master Drive Unit ............................................................................................................................................ 3
Brake............................................................................................................................................................... 3
Steering........................................................................................................................................................... 3
Mast ................................................................................................................................................................ 4
Frame.............................................................................................................................................................. 4
Travel Speeds...................................................................................................................................................... 4
Truck Weight........................................................................................................................................................ 4
Battery Specifications.......................................................................................................................................... 5
This section is for the following models:
MSW020/025-E [A895]
©2006 Yale Materials Handling Corp. i

4. 8000 YRM 1049 Hydraulic Oils
Lift and Hydraulic System Specifications
Specification MSW020-E MSW025-E
Motor Power 2.2 kW 2.2 kW
Hydraulic Relief Pressure 200 bar (2900 psi) 200 bar (2900 psi)
Lifting Speed1
With Load 28 28
Without Load 50 50
Lowering Speed2
With Load 60 60
Without Load 56 56
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 3.6 liter (0.95 gal)
1
Feet per Minute (+10%, 5%)
2
Feet per Minute (±10%)
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 32 to 120 C (89.6 to 184.0 F) 0 to 120 C (32.0 to 184.0 F)
Pour Point Maximum 15 C (5.0 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

5. Gear Oils 8000 YRM 1049
Master Drive Unit Specifications
Oil Specification
Gear Ratio Capacity
Standard CS/Freezer
42.2:1 189 ml (6.4 oz) 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

6. 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
Lift Truck Model Capacity Drive Tire Load Wheel
MSW020-E 907 kg (2000 lb) 102 × 70 mm (4.0 × 2.75 in.)
MSW025-E 1134 kg (2500 lb)
9 × 4 in. Molded Rubbera
9 × 5 in. Press-on Rubberb
9 × 4 in. Molded Poly
9 × 5 in. Press-on Poly
9 × 5 in. Press-on Siped Poly
102 × 70 mm (4.0 × 2.75 in.)
a
Standard for MSW020-E
b
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)
Traction Motor Gear Retaining Nut
26 N•m (19 lbf ft)
Traction Motor Mounting Capscrew
10 N•m (7 lbf ft)
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)
Gear Case Cover Capscrews
23 N•m (17 lbf ft)
Pivot Spindle Mounting Capscrews
23 N•m (17 lbf ft)
BRAKE
Installation Screws (3 each)
2.8 N•m (25 lbf in)
STEERING
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

7. Truck Weight 8000 YRM 1049
Control Arm Support Bracket Pivot Pins (2 each)
142 ±7 N•m (105 ±5 lbf ft)
MAST
Lift Cylinder Gland
375 N•m (277 lbf ft)
Lower Mast Installation Capscrews (2 each)
298.28 N•m (220 lbf ft)
Wear Strip Capscrews
10 N•m (7 lbf ft)
FRAME
Straddle Arm Mounting Bolts
300 N•m (221 lbf ft)
Travel Speeds
Travel Speeds (MPH), ±10%
Mode 1 Mode 2 Mode 3 Optional
Creep
Mode
Truck Capacity
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)
MSW020-E With Standard Battery Pack 1021 kg (2250 lb)
MSW025-E Without Battery 907 kg (2000 lb)
4

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9. 8000 YRM 1049 Battery Specifications
Battery Specifications
Figure 1. Battery Compartment Dimensions
Battery and Battery Compartment Dimensions
Battery Compartment Battery
Dimensions Length (X) Width (Y) Amperage Weight
Model
Length
(X)
mm (in.)
Width
(Y)
mm (in.)
Height
Min1
mm (in.)
Max
mm (in.)
Min1
mm (in.)
Max
mm (in.)
Max
kwh
(amp hr)
Min
kg (lb)
Max
kg (lb)
720 (28.3) 205 (8) Open 640 (25.2) 714 (28.1) 143 (5.6) 200 (7.8) 11.9 (510) 141 (310) 170 (375)
MSW020-E
720 (28.3) 230 (9) Open 640 (25.2) 714 (28.1) 168 (6.6) 224 (8.8) 11.9 (510) 159 (350) 259 (570)
1
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