Maintenance

FRAME
MCW025/030/040-E [C819];
MSW030/040-E [C820];
MRW020/030-E [C821]

PART NO. 524167547 100 YRM 1024

 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!
Frame Table of Contents

TABLE OF CONTENTS

General................................................................................................................................................................ 1
Features (MSW030/040-E and MRW020/030-E)............................................................................................ 1
Features (MCW025/030/040-E) ...................................................................................................................... 1
Frame Repair....................................................................................................................................................... 4
Painting Instructions ............................................................................................................................................ 4
Label Replacement.............................................................................................................................................. 4
Battery Compartment .......................................................................................................................................... 7
Battery Roller Option....................................................................................................................................... 7
Remove....................................................................................................................................................... 7
Install .......................................................................................................................................................... 7

This section is for the following models:

MCW025/030/040-E [C819];
MSW030/040-E [C820];
MRW020/030-E [C821]

©2003 Yale Materials Handling Corp. i

100 YRM 1024 General

General
This manual describes the frame for the MSW030/ 4. Basearm Width
040-E, MRW020/030-E, and MCW025/030/040-E lift a. 940 mm (37 in.)
trucks. These models have a main frame weldment b. 1092 mm (43 in.)
and a mast weldment. The main frame weldment c. 1143 mm (45 in.)
for the MCW025/030/040-E differs considerably from d. 1245 mm (49 in.)
the main frame weldments of the MSW030/040-E e. 1295 mm (51 in.)
and MRW020/030-E. The MSW030/040-E and f. 1448 mm (57 in.)
MRW020/030-E have base arm weldments that extend
under the load. The MCW025/030/040-E have an 5. Load Center
extended main frame weldment to counterbalance the a. 406 mm (16 in.)
load and larger load wheels mounted by trunnion cap b. 457 mm (18 in.)
assemblies near the front of the unit. See Figure 1 or c. 533 mm (21 in.)
Figure 2. d. 610 mm (24 in.)

FEATURES (MSW030/040-E AND FEATURES (MCW025/030/040-E)

MRW020/030-E) The MCW025/030/040-E main frame has mounts for:
The Mast Weldment
The MSW030/040-E and MRW020/030-E main frames
The Electrical System Parts
have mounts for:
The Hydraulic Pump and Motor Assembly
The Mast Weldment
The Master Drive Unit
The Electrical System Parts
The Load Wheels
The Hydraulic Pump and Motor Assembly
The Tilt Cylinders
The Master Drive Unit
The Load Wheels
The MCW025/030/040-E frames share a common 13.5
Based on model and capacities, MSW030/040-E and inch battery compartment and load wheel configuration
MRW020/030-E frames are available in combinations and are available in combinations of the following:
of the following:
1. Lifting Capacity
1. Lifting Capacity 1134 kg (2500 lb)
a. 907.2 kg (2000 lb) 1360.8 kg (3000 lb)
b. 1360.8 kg (3000 lb) 1814.4 kg (4000 lb)
c. 1814.4 kg (4000 lb)
2. Wheel Base
2. Battery Compartment Size a. 1245 mm (49 in.)
a. 229 mm (9.0 in.) b. 1372 mm (54 in.)
b. 343 mm (13.5 in.) c. 1549 mm (61 in.)

3. Load Wheels 3. Load Center

a. Single a. 406 mm (16 in.)
b. Tandem b. 457 mm (18 in.)
c. 533 mm (21 in.)
d. 610 mm (24 in.)

1
General 100 YRM 1024

1. TRUNNION CAP 6. BASE ARM WELDMENT

2. BATTERY COMPARTMENT 7. SINGLE LOAD WHEEL CONFIGURATION
3. BATTERY CONNECTOR LOCATION 8. TANDEM LOAD WHEEL CONFIGURATION
4. DISPLAY AND KEY SWITCH BRACKET (OPTIONAL)
5. MASTER DRIVE UNIT MOUNTING BRACKET

Figure 1. Frame Weldment (MSW030/040-E and MRW020/030-E)

2
100 YRM 1024 General

1. TRUNNION CAP 4. DISPLAY AND KEY SWITCH BRACKET

2. BATTERY COMPARTMENT 5. MASTER DRIVE UNIT MOUNTING BRACKET
3. BATTERY CONNECTOR LOCATION

Figure 2. Frame Weldment (MCW025/030/040-E)

3
Label Replacement
Frame Repair
WARNING
Forklift truck frames and components may have
polyurethane paint. Welding, burning, or other heat
sufficient to cause thermal decomposition of the
paint may release isocyanates. These chemicals
are allergic sensitizers to the skin and respiratory
tract and overexposure may occur without odor
warning. Always utilize good industrial hygiene
practices including removal of all paint (prime and
finish coats) to the metal around the area to be
welded, local ventilation, and/or supplied-air respi-
ratory protection when repairing the frame.
Painting Instructions
WARNING
Always use solvents and paints in an area with ven-
tilation. Do not use solvents or paints near heat or
fire.
WARNING
Cleaning solvents can be flammable and toxic and
can cause skin irritation. Wear protection for eyes
and skin. Always follow the recommendations of
the manufacturer when using cleaning solvents.
1. Remove all dirt from the surface to be painted.
Clean the area to be painted using a solvent for
painted surfaces. Remove all oil and grease.
Label Replacement
WARNING
Replace damaged Warning or Caution labels imme-
diately.
If labels or information plates are missing or damaged,
they must be replaced.
NOTE: The nameplate cover is installed using rivets.
Remove old rivets before installing a new name-
plate. See your Yale lift truck dealer to make sure the
nameplate information is correct and complete before
installing a new nameplate. Fasten the nameplate
cover with the rivet heads outside.
4
100 YRM 1024
WARNING
Do not make any repairs or adjustments unless you
have proper authorization and training. Repairs and
adjustments that are not correct can cause a dan-
gerous operating condition. Do not operate a lift
truck that needs repairs. Report the need for re-
pairs to your supervisor immediately. If repair is
necessary, put a DO NOT OPERATE tag on the con-
trol handle. Remove the key from the key switch.
Most lift truck repairs are performed on the individual
components that are bolted to the frame and not to the
frame itself.
2. Remove the top surface of paint and all rust from
the metal using sandpaper. Paint all metal sur-
faces where the paint is completely removed using
primer. Apply the primer before applying the color
paint.
3. Protect all surfaces that will not be painted. Do
not paint cylinder rods, cables, labels, plates, or
controls.
4. Paint the surfaces using Yale paint. Follow the di-
rections on the container. Paint all surfaces the
original color.
1. Make sure the surface is dry and has no oil or
grease. Do not use solvent on new paint. Clean
the surface of old paint using a cleaning solvent.
2. Remove the paper from the back of the label. Do
not touch the adhesive surface.
3. Carefully hold the label in the correct position above
the surface. The label cannot be moved after it
touches the surface. Put the label in the correct po-
sition on the surface. Make sure all air is removed
from under the label and the corners and edges are
tight. See Figure 3 and Figure 4.
100 YRM 1024 Label Replacement

1. LABEL - FORK WARNING 10. COVER - NAMEPLATE

2. LABEL - MOVING MAST WARNING 11. NAMEPLATE
3. LABEL - WARNING AND INSTRUCTION 12. RIVET
4. LABEL - YALE 13. LABEL - YALE
5. LABEL - DASH 14. LABEL - MANUAL LOWERING
6. OPERATOR’S MANUAL 15. LABEL - SNOWFLAKE
7. LABEL - PATENTS AND TRADEMARKS 16. LABEL - SIDESHIFT
8. LABEL - BATTERY DISCHARGE NOTICE 17. LABEL - TILT
9. UL PLATE - E CONSTRUCTION

Figure 3. Labels and Decals (MSW030/040-E and MRW020/030-E )

5
Label Replacement 100 YRM 1024

1. LABEL - FORK WARNING 10. COVER - NAMEPLATE

2. LABEL - MOVING MAST WARNING 11. NAMEPLATE
3. LABEL - WARNING AND INSTRUCTION 12. RIVET
4. LABEL - YALE 13. LABEL - YALE
5. LABEL - DASH 14. LABEL - MANUAL LOWERING
6. OPERATOR’S MANUAL 15. LABEL - SNOWFLAKE
7. LABEL - PATENTS AND TRADEMARKS 16. LABEL - SIDESHIFT
8. LABEL - BATTERY DISCHARGE NOTICE 17. LABEL - TILT
9. UL PLATE - E CONSTRUCTION

Figure 4. Labels and Decals (MCW025/030/040-E)

6
100 YRM 1024
Battery Compartment
WARNING
Batteries are heavy. Use care to avoid injury. Al-
ways use a battery roller stand or tray when trucks
are equipped with optional battery rollers or slide.
The battery compartment is available in two sizes:
229 mm (9.0 in.) or 343 mm (13.5 in.). Any fluids on
or around the battery is an indication that electrolyte
is spilling, leaching, or leaking out. Leaking batteries
must be repaired or replaced.
For instructions for changing the battery and adjust-
ing the battery spacers, refer to Periodic Maintenance
8000 YRM 1027.
BATTERY ROLLER OPTION
Remove
1. Remove battery.
2. Remove side gates to gain access to capscrews.
3. Remove capscrews, washers, lockwashers, and
nuts.
Battery Compartment
4. Remove battery tray.
5. Clean battery compartment and battery tray thor-
oughly using a cloth or brush and a solution of bak-
ing soda and water.
6. Rinse area with water and dry with a clean cloth.
Install
1. Align battery tray with slots in floor of battery com-
partment. Refer to Figure 5.
2. Install capscrews (3), washers (4), lockwashers (5),
and nuts (6).
3. Torque nuts (6) to 101 N•m (75 lbf ft).
4. Install spacers to side gates using capscrews (9),
lockwashers (10), and nuts (11).
5. Torque nuts (11) to 11 N•m (8 lbf ft).
6. Install side gates.
7. Install battery.
7
Battery Compartment 100 YRM 1024

1. BATTERY ROLLER TRAY 7. SIDE GATE

2. ROLLER 8. SPACER
3. CAPSCREW 9. CAPSCREW
4. WASHER 10. LOCKWASHER
5. LOCKWASHER 11. NUT
6. NUT

Figure 5. Battery Roller Installation

8
 Yale Materials Handling Corp.
1400 Sullivan Dr., Greenville, NC 27834-2011

100 YRM 1024 4/03 (12/02)(11/02) Printed in U.S.A.