The document provides instructions for repairing frames on forklifts. It describes the main components that attach to the frame, including the lifting mechanism, electrical system, hydraulic pump, and master drive unit. Procedures are outlined for separating a fork frame or drive unit frame if damaged while the rest of the truck is still usable. The steps include removing pins and carefully separating the frames. Reassembly involves replacing the pins in reverse order. Safety warnings are also provided.

1. SERVICE REPAIR
W45Z [C215]

2. 100 SRM 1015 General
General
DESCRIPTION
The main frame has mounts for the lifting mech-
anism, the electrical system parts, the hydraulic
pump assembly, and the master drive unit (MDU).
Repair procedures for major systems/parts that fas-
ten to the main frame are found in separate SRM
manuals. Models with a fork frame weldment have
mounts for the lifting mechanism. See Figure 1. The
fork frame weldment is fastened to the main frame
by the links of the lifting mechanism. The base of
the forks and the battery end of the weldment are
lifted by the cylinder to raise the load. At the same
time, the fork tips are lifted by linkage operating the
load wheel assembly. There is also a mount for the
optional casters. The mounting holes for the casters
are in the main frame weldment.
1. FORKS
2. FRAME
3. UPPER COVER
4. MOTOR COVER RH
5. MOTOR COVER LH
6. COUNTERSUNK CAPSCREW
7. LOWER COVER
8. WASHER
9. BUTTON HEAD CAPSCREW
Figure 1. Frame Weldment and Covers W40Z, W45Z, and W50Z
1

3. Frame Separation and Assembly 100 SRM 1015
Frame Repair
WARNING
Forklift truck frames and components may
have polyurethane paint. Welding, burning, or
other heat sufficient to cause thermal decom-
position 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 in-
cluding removal of all paint (prime and finish
coats) to the metal around the area to be
welded, local ventilation, and/or supplied-air
respiratory protection when repairing the
frame.
WARNING
Do not make any repairs or adjustments un-
less you have proper authorization and train-
ing. Repairs and adjustments that are not cor-
rect can cause a dangerous operating condi-
tion. Do not operate a lift truck that needs re-
pairs. Report the need for repairs to your su-
pervisor immediately. If repair is necessary,
put a DO NOT OPERATE tag on the control
handle. Remove the key from the key switch.
Most lift truck repairs are performed on the individ-
ual components that are bolted to the frame and not
to the frame itself.
FEATURES
The lift truck frames are offered in combinations of
the following options:
1. Weight Capacity
a. 1814 kg (4000 lb)
b. 2041 kg (4500 lb)
c. 2268 kg (5000 lb)
2. Fork Length
a. 900 mm (36 in.)
b. 1050 mm (42 in.)
c. 1200 mm (48 in.)
d. 1400 mm (54 in.)
e. 1500 mm (60 in.)
3. Battery Compartment Size
a. 206 mm (8 in.) × 724 mm (29 in.)
b. 206 mm (8 in.) × 804 mm (32 in.)
c. 232 mm (9 in.) × 724 mm (29 in.)
Frame Separation and Assembly
SEPARATION
In some cases a fork frame or a drive unit frame may
be damaged, while the rest of the truck is still usable.
The two frames may be separated from each other by
using the following steps.
1. Raise the motorized lift truck to its maximum
height. Turn the key to the OFF position. Dis-
connect the battery.
2. Remove the drive unit compartment covers.
3. Position blocks under both sides of the truck in
the area of the battery compartment and under
both forks. See How to Put Lift Truck on Blocks
in Periodic Maintenance 8000 SRM 1009.
4. Remove the battery.
5. Remove the top clevis pin securing the hydraulic
cylinder to the frame. See Hydraulic Cylinder in
Walkie Hydraulic Systems 1900 SRM 1018.
6. Remove both pivot pins securing the upper link
to the drive unit frame. See Upper Link, Remove
in Lifting Mechanism 4000 SRM 1008.
7. Remove both drive unit frame pivot pins secur-
ing the rocker arm to the drive unit frame. See
Rocker Arm, Remove in Lifting Mechanism
4000 SRM 1008.
8. Carefully move one of the frames away from the
other.
ASSEMBLY
1. Align both frames so the pins may be installed to
assemble the frames to each other.
2. Install both drive unit frame pivot pins to se-
cure the rocker arms to the drive unit frame.
See Rocker Arm, Install in Lifting Mechanism
4000 SRM 1008.
2

4. 100 SRM 1015 Battery Compartment
3. Install both pivot pins to secure the upper link to
the drive unit frame. See Upper Link, Install in
Lifting Mechanism 4000 SRM 1008.
4. Install the pivot pin to secure the hydraulic cylin-
der to the fork frame. See Hydraulic Cylinder, In-
stall in Walkie Hydraulic Systems 1900 SRM
1018.
5. Install the battery.
6. Install the drive unit compartment covers.
7. Connect the battery and turn the key switch to
the ON position.
8. Remove the blocks and lower the lift truck to the
floor.
9. Test the operation of the truck before returning
to service.
Battery Compartment
BATTERY COMPARTMENT
SPECIFICATIONS
WARNING
Batteries are heavy. Use care to avoid injury.
Always use a battery roller stand or tray when
trucks are equipped with optional battery
rollers or slide. Always wear protective cloth-
ing and eye protection when working with or
near the battery.
The battery compartment is available in two sizes:
205 mm (8 in.) or 230 mm (9 in.).
Battery rollers may be installed in the floor of the
battery compartment. Gates are installed on both
sides of the battery to prevent movement on the
rollers during operation. Spacers are available to
secure batteries that fit loosely in the battery com-
partment.
The battery compartment must be kept clean to en-
sure proper operation and safety. Any fluids on or
around the battery is an indication that electrolyte
is spilling or leaking out. Leaking batteries must be
repaired or replaced and the battery compartment
must be cleaned.
WARNING
Never place tools or other objects on top of the
battery.
Contact of objects between the battery posts can re-
sult in personal injury and severe damage to the lift
truck. Never allow tools or other objects to be placed
on top of the battery. Water levels in the battery must
be checked regularly and filled to specifications if the
level is too low.
NOTE: Battery water levels can be maintained with-
out removing the battery from the truck.
See Periodic Maintenance 8000 SRM 1009 for
more information on regularly scheduled battery
maintenance.
CHANGING THE BATTERY
WARNING
Batteries are heavy. Use care to avoid injury.
Always use a battery roller stand or tray when
trucks are equipped with optional battery
rollers or slide.
WARNING
Always wear protective clothing, gloves, and
goggles when handling batteries and elec-
trolyte.
Make sure the capacity of the crane and spreader bar
is greater than the weight of the battery. The weight
of the battery is normally shown on the battery case.
The maximum battery weight is shown on the lift
truck nameplate. The spreader bar must NOT be
made of metal, or it must have insulated straps. See
Figure 2.
3

5. Label Replacement 100 SRM 1015
1. CRANE
2. SPREADER BAR
3. INSULATED
STRAPS
4. BATTERY
Figure 2. Changing the Battery
For the following instructions, refer to Figure 2.
Remove
1. Move lift truck under overhead crane or other
suitable lifting device.
2. Block drive tire to prevent movement of lift truck.
3. Turn key switch OFF, disconnect battery connec-
tor, and move it out of the way.
4. Loosen one of the battery spacers and move it out
of the way. See Figure 2.
5. Connect spreader bar to battery using insulated
straps and lift battery out of lift truck.
Install
WARNING
Before connecting the battery, make sure the
key switch is in the OFF position and the
control handle is in the UP position (brake
applied).
CAUTION
The replacement battery must fit the battery
compartment correctly. Adjust the brackets
on each side of the battery and tighten the
capscrews, lockwashers, and nuts to retain the
battery.
CAUTION
Make sure the voltage and weight of the re-
placement battery is correct as shown on the
nameplate.
Make sure the battery is the correct size and weight
for the lift truck.
1. Remove any obstructions in battery compart-
ment (i.e., battery cables or tools).
2. Lower new battery into battery compartment.
3. Connect battery cable connector. Adjust location
of battery to allow proper connection of cables.
4. Adjust the brackets on each side of the battery
and tighten the capscrews, lockwashers, and
nuts to retain the battery.
5. Remove spreader bar and insulated straps from
battery.
Battery Spacer Adjustment
The battery spacers are designed to hold the battery
in place during normal operation. The spacers are
adjusted by adding or removing spacers as required
to prevent the battery from moving.
Label Replacement
WARNING
Replace damaged Warning or Caution labels
immediately.
If labels or information plates are missing or dam-
aged, they must be replaced. See Figure 3.
NOTE: The nameplate cover is installed using rivets.
Remove old rivets before installing a new nameplate
cover. See your Hyster lift truck dealer to make sure
the nameplate cover information is correct and com-
plete before installing a new nameplate cover. Fas-
ten the nameplate cover with the rivet heads outside.
4

6. 100 SRM 1015 Label Replacement
1. Make sure the surface is dry and free of 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.
NOTE: The label cannot be moved after it touches the
surface.
3. Carefully hold the label in the correct position
above the surface. Put the label in the correct
position on the surface. Make sure all air is re-
moved from under the label and the corners and
edges are tight.
1. LABEL (HYSTER)
2. COVER
3. LABEL (WARNING)
4. RIVET
5. LABEL (PINCH WARNING)
6. LABEL (US PATENTS AND TRADEMARKS)
7. LABEL (DASH)
8. NAMEPLATE LABEL
9. OPERATORS MANUAL
10. LABEL (HYSTER)
11. LABEL (BATTERY DISCHARGE NOTICE)
Figure 3. Label and Decal Location
5

7. Load Wheels 100 SRM 1015
Painting Instructions
WARNING
Always use solvents and paints in an area with
ventilation. 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. When using cleaning sol-
vents, always follow the recommendations of
the manufacturer.
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.
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 us-
ing 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 Hyster paint. Follow the
directions on the container. Paint all surfaces the
original color.
Load Wheels
REMOVE
WARNING
Put blocks under both forks and on both sides
of the drive tire. The blocks must prevent the
lift truck from falling and causing personal in-
jury or property damage.
1. Use the lift button to raise the lift truck to its
maximum height.
2. Put blocks under both forks and on both sides of
the drive tire. See the section How to Put a Lift
Truck on Blocks in the Periodic Maintenance
manual.
3. Drive the roll pin retaining the axle shaft to the
rear axle link out of the link and axle.
4. Lower the hoist cylinder using the lower button.
This will raise the load wheels off the floor.
5. Move the key to the OFF position. Disconnect
the battery. Remove the battery.
6. Remove the axle shaft. Remove bearings and
load wheel from the link. It may be necessary
to drive the bearing out of the wheel. Drive the
bearing out from the opposite sides. See Figure 4.
7. Remove all old lubricant. Clean and inspect all
parts. Replace all defective parts.
INSTALL
1. Prelubricate the bearings with the recommended
grease. Install the bearings in the load wheel.
2. Align the load wheel and bearings inside the link
and insert the axle shaft.
3. Install the roll pin in the link and through the
axle shaft.
4. Raise the load wheels. Lubricate the load wheel.
5. Install the battery in the battery compartment
and connect the battery.
6. Remove the blocks from under the forks and from
each side of the drive tire. Turn the key to the
ON position and use the lower button to lower
the lift truck to its minimum height. The truck
should lift and lower evenly.
7. Test the operation of the motorized hand truck
before returning the truck to service.
The function of the load wheels is further explained
in Lifting Mechanism 4000 SRM 1008.
6

8. 100 SRM 1015 Load Wheels
1. LOAD WHEEL
2. FITTING
3. ROLLER
4. BEARING
5. BUSHING
6. AXLE
7. FITTING
8. PIN
Figure 4. Load Wheel and Link Assembly
7

9. 4000 SRM 1008 General
General
LIFT LINKAGE
This section has the description and repair proce-
dures for the W40/45/50Z units. The lifting mecha-
nism is operated by the hydraulic system. Hydraulic
fluid extends the lift cylinder, operates the lift link-
age, and raises the forks.
On all motorized lift trucks, when the lift button on
the control handle is depressed, the hydraulic pump
sends high pressure hydraulic fluid to the lift cylin-
der. This action extends the cylinder, operates the lift
linkage, and raises the forks. At the same time, the
rocker arms and the rear links mounted under the
drive unit platform are pulled upward. This causes
the push rod assembly to be pushed toward the load
wheel end of the truck. The movement of the push
rods in this direction causes the load wheels to pivot
down on their pivot pins. See Figure 1.
1. LOWER LINK (RH)
2. LOWER LINK (LH)
3. FORK
4. LOAD WHEEL
Figure 1. Lift Linkage
1

10. Load Wheel 4000 SRM 1008
Load Wheel
REMOVE
WARNING
Put blocks under both forks and on both sides
of the drive tire. The blocks must prevent the
lift truck from falling and causing personal in-
jury or property damage.
1. Remove the battery from the lift truck. Position
the battery close enough to the lift truck to allow
power cable connection during servicing. Con-
nect the battery and turn the key switch to the
ON position.
2. Use the lift button to raise the lift truck to its
maximum height.
3. Put blocks under both forks and under the drive
end of truck. See the section How to Put a Lift
Truck on Blocks.
4. Press the lower button just enough to relieve
pressure from the load wheels.
5. Move the key to the OFF position. Disconnect
the battery.
6. Drive out the roll pin retaining the load wheel
axle shaft to the link. Repeat for other side.
7. Remove the axle shaft and bushings from the
link. Remove bearings and load wheel assem-
bly from the link. It may be necessary to drive
the bearing out of the wheel using a soft punch.
Drive the bearing out from the opposite side. See
Figure 2.
NOTE: Some models are equipped with sealed bear-
ings. Do not attempt to clean or lubricate sealed
bearings. Sealed bearings in need of service must be
replaced.
8. Remove all old lubricant. Clean and inspect all
parts. Replace all defective parts.
INSTALL
NOTE: Some models are equipped with sealed bear-
ings. Do not attempt to clean or lubricate sealed
bearings. Sealed bearings in need of service must be
replaced.
1. Prelubricate the bearings with the recommended
grease. Install bearings into the load wheel and
install the bushings into the bearings.
2. Position the load wheel assembly into the link.
Insert the axle shaft through the link, bushings,
and bearings. Insert a punch to align the roll pin
hole in the axle shaft with the hole in the link.
3. Install the roll pin through the link to secure the
axle shaft.
4. Reconnect the battery. Move the key to the ON
position.
5. Press the lift button to fully extend the lift link.
6. Remove the blocks from under the forks and
drive end of truck. Lubricate the load wheel and
link fittings then press the lift and lower buttons
to raise and lower the forks. The truck should
lift and lower evenly.
7. Install the battery in the battery compartment.
8. Test the operation of the motorized hand truck
before returning the truck to service.
2

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12. 4000 SRM 1008 Rear Link and Load Wheel
1. LINK
2. GREASE FITTING
3. ROLLER
4. BEARING
5. BUSHING
6. AXLE SHAFT
7. FITTING
8. ROLL PIN
Figure 2. Load Wheel and Link Assembly
Rear Link and Load Wheel
REMOVE
WARNING
Put blocks under both forks and on both sides
of the drive tire. The blocks must prevent the
lift truck from falling and causing personal in-
jury or property damage.
1. Remove the battery from the lift truck. Position
the battery close enough to the lift truck to allow
power cable connection during servicing. Con-
nect the battery and turn the key switch to the
ON position.
2. Use the lift button to raise the lift truck to its
maximum height.
3. Put blocks under both forks and under the drive
end of truck. See the section How to Put a Lift
Truck on Blocks.
4. Press the lower button just enough to relieve
pressure from the load wheels.
5. Move the key to the OFF position. Disconnect
the battery.
3

13. Compression Rod 4000 SRM 1008
6. Disconnect the load wheel link from the compres-
sion rod yoke:
a. Remove the roll pin securing the pivot pin in
the yoke.
b. Remove the pivot pin.
7. Remove the load wheel link from the fork frame:
a. Remove the roll pin securing the link and exit
roller to the fork.
b. Drive out the roll pin securing the pivot pin
to the fork.
c. Remove the pivot pins.
d. Remove any bushings as necessary.
8. Disassemble the load wheel. See Load Wheel.
9. Remove all old lubricant. Clean and inspect all
parts for damage. Replace all defective parts.
INSTALL
1. Assemble the load wheel assembly to the link.
See Load Wheel.
NOTE: Some models are equipped with bushings
in the load roller link where the compression rod
yoke attaches. Install new bushings if removed as
required.
2. Install the load wheel and link assembly to the
fork:
a. Align the pallet exit roller and load wheel
link with mounting holes in fork.
b. Install the connecting pivot pin and align
holes with a punch.
c. Secure with the roll pin.
3. Connect the load wheel link with the compres-
sion rod:
a. Check condition of yoke components includ-
ing bushings and compression rod jam nuts.
Replace as required.
b. Align the compression rod yoke and the load
wheel link.
c. Install the connecting pivot pin and secure
with the roll pin.
4. Connect the power cables and turn the key
switch to the ON position. Press the lift button
to fully extend the load wheels. Remove the
blocks from under the forks and from each side
of the drive tire.
5. Lubricate the load wheel link fittings. Lift and
lower the lift truck to check for proper operation.
The truck should lift and lower evenly.
6. Install the battery into the battery compartment.
Compression Rod
REMOVE
WARNING
Put blocks under both forks and on both sides
of the drive tire. The blocks must prevent the
lift truck from falling and causing personal in-
jury or property damage.
WARNING
Batteries are heavy and can cause a personal
injury. Use care to avoid injury. Do NOT put
hands, arms, feet, and/or legs between the bat-
tery and a solid object. Make sure the capacity
of the lifting device and spreader bar is greater
than the weight of the battery. The weight of
the battery is normally shown on the battery
case. The maximum battery weight is shown
on the lift truck nameplate. The spreader bar
must NOT be made of metal or it must have in-
sulated straps.
1. Use the lift button to raise the lift truck to its
maximum height.
2. Put blocks under both forks and on both sides of
the drive tire. See How to Put a Lift Truck on
Blocks.
3. Lower the hoist cylinder using the lower button.
This will raise the load wheels off the floor.
4. Move the key to the OFF position. Disconnect
the battery. Remove the battery.
4

14. 4000 SRM 1008 Lower Link
5. Remove the roll pin retaining the load wheel link
pivot pin to the fork frame. Remove the pivot pin.
6. Remove drive unit and lower cover.
7. Remove the roll pin retaining the lower link pivot
pin to the compression rod. Remove the pivot pin.
8. Remove all old lubricant. Clean and inspect all
parts. Replace defective parts.
INSTALL
1. Install pivot pin retaining lower link and com-
pression rod. Install roll pin.
2. Align and install the pivot pin connecting the
compression rod and the load wheel. Install roll
pin.
3. Install the pivot pin connecting the load wheel
link and pallet entry/exit roller and install the
roll pin to retain the pivot pin.
4. Raise the load wheels. Lubricate the load wheel
and all linkage pivot pins.
5. Install the battery in the battery compartment
and connect the battery.
6. Remove the blocks from under the forks and from
each side of the drive tire. Turn the key to the
ON position and use the lower button to lower
the lift truck to its minimum height. The truck
should lift and lower evenly.
7. Test the operation of the motorized hand truck
before returning the truck to service.
Lower Link
REMOVE
WARNING
Batteries are heavy and can cause a personal
injury. Use care to avoid injury. Do NOT put
hands, arms, feet, and/or legs between the bat-
tery and a solid object. Make sure the capacity
of the lifting device and spreader bar is greater
than the weight of the battery. The weight of
the battery is normally shown on the battery
case. The maximum battery weight is shown
on the lift truck nameplate. The spreader bar
must NOT be made of metal or it must have in-
sulated straps.
WARNING
Put blocks under both forks and on both sides
of the drive tire. The blocks must prevent the
lift truck from falling and causing personal in-
jury or property damage.
1. Use the lift button to raise the lift truck to its
maximum height.
2. Move the key to the OFF position. Disconnect
and remove the battery.
3. Put blocks under both forks and on both sides of
the drive tire. See the section How to Put a Lift
Truck on Blocks.
4. Remove covers.
5. Remove the roll pin retaining the drive frame
pivot pin to the lower link. Use a drift to drive
the pivot pin out of the lower link and the drive
frame. See Figure 3.
6. Remove the roll pin retaining the lower link pin
to the fork frame. Drive the pin out of the frame
using a drift pin.
7. Remove the bushings from the lower link.
8. Remove all old lubricant. Clean and inspect all
parts. Replace all defective parts.
INSTALL
1. Install new bushings into the lower link using
the grease fitting hole as a guide.
2. Align the lower link with the fork frame and in-
stall the lower link pivot pin. Install the roll pin
to retain the pivot pin.
3. Align the lower link with the drive frame and
install the drive frame pivot pin. Install the roll
pin to retain the drive frame pivot pin.
4. Align the pull rod and the lower link and install
the pivot pin. Install the roll pin to retain the
pivot pin.
5. Lubricate the grease fittings.
5

15. Upper Link 4000 SRM 1008
6. Remove the blocks from under the forks and from
each side of the drive tire.
7. Install the battery in the battery compartment.
Connect the battery.
8. Turn the key to the ON position and use the
lower button to lower the lift truck to its mini-
mum height.
9. Test the operation of the motorized hand truck
before returning the truck to service.
1. FITTING
2. PIN
3. FITTING
4. PIVOT PIN
5. PIN
Figure 3. Lower Link
Upper Link
REMOVE
WARNING
Put blocks under both forks and on both sides
of the drive tire. The blocks must prevent the
lift truck from falling and causing personal in-
jury or property damage.
1. Disconnect the battery.
2. Put blocks under both forks and on both sides of
the drive tire. See the section How to Put a Lift
Truck on Blocks.
3. Remove the drive unit compartment cover to ac-
cess the upper link. See Figure 4.
4. Use a drift pin to remove the roll pin retaining
the pivot pin to the drive unit frame. Drive the
pivot pin out of the frame and upper link.
5. Remove the screw, washer, and nut retaining the
pivot pin to the fork frame. Drive the pivot pin
out of the fork frame and upper link.
6