service repair manual

1. SERVICE REPAIR
W40Z [B218]

2. 1600 SRM 1004 Special Precautions
General
The control handle assembly is designed to perform
several functions. The standard control handle in-
cludes the speed/direction control and buttons for the
horn, traction reversing, and hydraulic functions.
The control handle is connected to the Master Drive
Unit (MDU) and is used to steer the truck as it turns
the MDU. Move the control handle left or right to
turn the drive/steer tire and steer the truck. Con-
trols mounted in the handle are linked to the control
panel by a wiring harness that passes through the
center of the handle. The brake is applied when the
handle is in the full up or down position.
A bottom-mounted control handle assembly is used
on the W20-25ZA, W25-30ZA2, and W40-45-50Z. The
handle is designed to be used while the operator is
walking beside the lift truck.
Special Precautions
WARNING
To avoid personal injury and prevent electri-
cal shock, perform the following steps before
troubleshooting or adjusting and before con-
necting or disconnecting a handset or personal
computer.
CAUTION
To avoid controller damage, always disconnect
the battery, discharge the capacitor, and never
put power to the controller while any power
wires are disconnected. Never short any con-
troller terminal or motor terminal to the bat-
tery. Make sure to use the proper procedure
when servicing the controller.
1. Turn the key switch to the OFF position and dis-
connect the battery.
2. Discharge the capacitors in the controllers by
connecting a 200-ohm, 2-watt resistor across
the controller’s B+ and B terminals. DO NOT
short across the motor controller terminals with
a screwdriver or jumper wire. See Figure 1 and
Figure 2.
3. Remove the 200-ohm, 2-watt resistor before re-
connecting the battery.
1. POSITIVE CONNECTION
2. NEGATIVE CONNECTION
3. INSULATED JUMPER WIRES
4. 200-OHM, 2-WATT RESISTOR
Figure 1. Discharging Controller - W40Z
1

3. Control Handle 1600 SRM 1004
Figure 2. Discharging Controller - W20ZA,
W25ZA, W25ZA2, W30ZA2, W45Z, and W50Z
Legend for Figure 2
1. NEGATIVE CONNECTION
2. POSITIVE CONNECTION
3. 200-OHM, 2-WATT RESISTOR
4. INSULATED JUMPER WIRES
Control Handle Head
Refer to the section Electrical System 2200 SRM 1007 for instructions on removing and installing the control
handle head from the control handle. The instructions for disassembly and assembly of the control handle head
can be located in the same section.
Control Handle
REMOVE
WARNING
The gas springs used on the control handle are
installed under tension and can release with
enough force to cause personal injury or prop-
erty damage.
WARNING
The capacitor in the transistor controller can
hold an electrical charge after the battery is
disconnected. To prevent electrical shock and
personal injury, discharge the capacitor before
inspecting or repairing any component in the
drive unit compartment. Wear safety glasses.
Make certain the battery has been discon-
nected. Refer to Figure 1 and Figure 2 in the
Special Precautions section of this manual.
1. Move the lift truck to a safe, level area and block
the wheels to prevent movement.
2. Turn the key switch to the OFF position and dis-
connect the battery.
2

4. 1600 SRM 1004 Control Handle
3. Remove the drive unit compartment covers and
MDU covers.
4. Discharge the capacitor in the controller by con-
necting a 200-ohm, 2 watt resistor between the
B+ and B connectors on the controller.
5. Disconnect the control handle wiring harness
plug and the control handle arm prox switch
plug located on top of the drive motor.
For the following instructions refer to Figure 3.
6. Remove the rubber bumper retaining screw and
wire clamp.
7. If necessary, remove the control handle head. See
the section Electrical System 2200 SRM 1007,
Control Handle.
CAUTION
Discharging the gas spring is a destructive op-
eration.
8. Discharge and remove the gas spring. Refer to
Gas Spring.
9. Remove both threaded control arm pivot pins and
washers.
10. Remove the control arm from the support
bracket.
11. Remove two screws from the support bracket and
remove the control handle arm prox switch.
12. If bushings are worn, remove the bushings from
the support bracket pivot pin holes.
INSTALL
1. Install the new gas spring to the control handle
arm. Refer to Gas Spring.
2. If previously removed, install the bushings into
the support bracket pivot pin holes.
NOTE: Install the switch to the bracket with wire to
bottom of the bracket.
3. Install the control handle arm prox switch into
the mounting bracket and mount onto the sup-
port bracket with retaining screws. Leave retain-
ing screws loose until the control handle arm is
installed.
4. Install the bumper and wire clamp with retain-
ing screw and tighten to 10.5 N•m (93 lbf in).
5. If removed, install the control handle head. See
the section Electrical System 2200 SRM 1007,
Control Handle.
6. Install the control arm into the support bracket.
Apply Loctite® 242 to the threaded portion of the
pivot pins and install pivot pins. Torque to 142
±7 N•m (105 ±5 lbf ft).
7. Drive the pin through lower end of gas spring to
secure to support bracket.
8. Adjust control handle arm prox switch. Refer to
the section Electrical System 2200 SRM 1007,
Control Handle Arm Prox Switch - Install.
9. Install the MDU covers and drive unit compart-
ment covers.
10. Connect the battery and test the operation of the
lift truck prior to returning to service.
3

5. Control Handle 1600 SRM 1004
Figure 3. Control Handle Assembly
4

6. 1600 SRM 1004 Gas Spring
Legend for Figure 3
1. CONTROL HANDLE ARM
2. PIVOT PIN
3. WASHER
4. BUSHING
5. PIN
6. GAS SPRING
7. SCREW
8. LOCKWASHER
9. FLAT WASHER
10. RUBBER BUMPER
11. CONTROL HANDLE ARM
PROX SWITCH
12. MOUNTING BRACKET
13. SCREW
14. SCREW
15. CONTROL HANDLE HEAD
16. SCREW
17. LOCKWASHER
18. FLAT WASHER
19. SCREW
20. LOCKWASHER
21. WIRE CLAMP
22. ALLEN HEAD SCREW
Gas Spring
WARNING
Disconnect the battery by separating the bat-
tery connector before opening the compart-
ment cover and before inspecting or repairing
the electrical system. DO NOT place tool on
top of the battery. If a tool causes a short
circuit, the high-current flow from the battery
can cause personal injury or property damage.
WARNING
The capacitor in the traction motor controller
can hold an electrical charge after the battery
is disconnected. To prevent electrical shock
and personal injury, discharge the capacitor
before inspecting or repairing any component.
Make certain the battery has been discon-
nected and always wear safety glasses. See
Special Precautions in this section. DO NOT
attempt to discharge the capacitors by short-
ing the controller.
WARNING
The gas spring used on the control handle is
installed under tension and can release with
enough force to cause personal injury or prop-
erty damage.
Review the following procedures before removing the
gas spring.
DISCHARGING THE GAS SPRING
WARNING
Goggles and a face shield must be worn for per-
sonal protection as metal chips and hydraulic
lubricant may be ejected from the drill opera-
tion due to the high internal pressure.
CAUTION
The control handle return spring is charged
with pressurized gas and contains a hydraulic
oil lubricant.
NOTE: This process is a destructive operation to the
gas spring. A new gas spring must be used during
reassembly.
1. Check that the handle return spring is installed
and properly secure the control handle arm in the
full upright position. Remove the plastic plugs to
increase visibility of the gas spring.
CAUTION
DO NOT damage the control handle wiring har-
ness inside the control handle arm.
2. Locate and drill a 7 mm (0.25 in.) access hole
through the center of the control handle tube, ap-
proximately 50 mm (2 in.) below the existing ac-
cess hole.
WARNING
Contents are under pressure. This process may
eject metal chips and oil.
3. Locate the gas spring inside the control handle
through the newly drilled access hole and drill a
3 mm (0.125 in.) hole into the gas spring cylinder
shell to relieve pressure.
4. Clean up any discharged oil and dispose of in ac-
cordance with local regulations.
5

7. 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

8. 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

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10. 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

11. 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

12. 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

13. 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

14. 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