Hyster W40Z User manual

CAPACITIES AND

SPECIFICATIONS

W40Z [B218]; W45Z [C215];

W50Z [D215]

PART NO. 1499833 8000 SRM 1010

SAFETY PRECAUTIONS

MAINTENANCE AND REPAIR

•When lifting parts or assemblies, make sure all slings, chains, or cables are correctly

fastened, 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 Mainte-

nance 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 HYSTER 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!

Capacities and Specifications Table of Contents

TABLE OF CONTENTS

Hydraulic Oils .................................................................................................................................................... 1

Gear Oils............................................................................................................................................................. 2

Grease................................................................................................................................................................. 3

Hydraulic System............................................................................................................................................... 4

Weight................................................................................................................................................................. 4

Basic Truck Without Battery ........................................................................................................................ 4

Tires.................................................................................................................................................................... 5

Torque Specifications ......................................................................................................................................... 5

Caster Assembly ............................................................................................................................................ 5

Master Drive Unit ......................................................................................................................................... 5

Steering .......................................................................................................................................................... 5

Brake .............................................................................................................................................................. 5

Lift Mechanism.............................................................................................................................................. 5

Battery Specifications and Adjustments .......................................................................................................... 5

4000 LB - 24 Volt ........................................................................................................................................... 5

4500 - 12 Volt ................................................................................................................................................. 6

4500 and 5000 LB - 24 Volt ........................................................................................................................... 7

This section is for the following models:

W40Z [B218];

W45Z [C215];

W50Z [D215]

"THE

QUALITY

KEEPERS"

HYSTER

APPROVED

PARTS

8000 SRM 1010 Hydraulic Oils

Hydraulic Oils

W40/45Z (and W50Z Standard Construction Only)

Type For All Hydraulically Actuated Equipment

Ambient Air Temp. Condition Normal Cold Storage

Anticipated Ambient Air

Temperature Range 0to +43 C(+32 to +109 F) 0to 32 C(+32 to 26 F)

Actual Useable Operation Oil

Temperature Range 28 to +64 C(+18 to +147 F) 40 to +50 C( 40 to +122 F)

ASTM Viscosity Grade

Number/Index (Ref.) S-215/92 Minimum S-376 Minimum

Pour Point 29 C( 20 F) 60 C( 76 F)

Approved Sources

American (Amoco) Rykon Number 21 No Product

Atlantic Richfield (Arco) Duro AW-46 No Product

Burmah-Castrol Hyspin AWH-46 No Product

Chevron Oil Company Chevron AW Hyd. Oil 46 No Product

Cities Service (Citco) Pacemaker XD-20 No Product

Exxon Nuto H 46 Univis®HVI 26

Fiske Brothers Lubriplate HO-1 No Product

Gulf Harmony 48AW No Product

Houghton & Company Hydro Drive HP 200 No Product

Keystone (Pennwalt) KLC Number 5 No Product

Mobil Oil Co. (Mobil) DTE 25 No Product

Pennzoil Oil Co. Pennzoil AW 46 No Product

Phillips Petroleum Magnus A-215 No Product

Shell Tellus 46 No Product

Solene Ind. Lubricant H-205-B No Product

Sun Oil Co. (Sunoco) Sunvis 821 WR No Product

Texaco Rando HD-46 No Product

Valvoline Oil Co. Antiwear Number 20 No Product

Field Personnel Note: The hydraulic oils, as listed herein, are approved sources that meet or exceed

the specifications annotated. The use of hydraulic oils other than the suppliers and products listed

is unauthorized.

W50Z (Cold Storage/Arctic Package)

Type For All Hydraulically Actuated Equipment

Ambient Air Temp. Condition Cold Storage/Arctic Package

Anticipated Ambient Air Temperature Range 32 to 0 C( 26 to +32 F)

Gear Oils 8000 SRM 1010

W50Z (Cold Storage/Arctic Package)

Actual Useable Operation Oil Tem-

perature Range 40 to +50 C( 40 to +122 F)

Viscosity /Index

(Ref.) ASTM D 2270

376

Pour Point 60 C( 76 F)

Approved Sources

Exxon Univis®HVI 26

Field Personnel Note: The hydraulic oils, as listed herein, are approved sources that meet or exceed

the specifications annotated. The use of hydraulic oils other than the suppliers and products listed

is unauthorized.

Gear Oils

Operating Condition Standard/CS/Freezer/Food

Processing Arctic

SAE Grade 80W-90 75W-90

Type Multipurpose EP Multipurpose EP

Base Oil Conventional Petroleum Synthetic

MIL-Specification No. MIL-L-2105C MIL-L-2105C

API Service Classification GL-5 GL-5

Anticipated Ambient

Temperature 26 to +38 C( 15 to +100 F)

Most HYSTER lift truck

operations will fall within this

temperature range.

As low as 51 C( 60 F)

Primarily intended for cold storage

and/or Arctic conditions; can be

used as high as +32 C(+90F).

Approved Sources

Chevron Chevron Universal Gear

Lube 80W/90 No Product

Exxon Exxon Gear Oil GX 80W/90 No Product

Mobil Mobilube HD 80W/90 Mobilube SHC 75W/90

Pennzoil Pennzoil MP 4092 No Product

Phillips 66 Philube SMP Gear Oil 80W/90 No Product

Solene Lub. Inc. Solene Gear Oil #905 No Product

Sun Sunfleet GL-5 Gear Lube 80W/90 No Product

Union 76 Unocal MP Gear Lube LS 80W/90 No Product

Field Personnel Note: The products listed above are the approved sources that meet or exceed HYSTER

specifications. The use of products other than that listed above is unauthorized.

8000 SRM 1010 Grease

Grease

Fittings and Bearings

Application Standard/CS/Freezer Arctic/Food

Processing Steer Bearings

Approved Vendor Mobilgrease®28 Amsoil GHD®Amsoil GHD®

Oil Synthetic Synthetic Synthetic

Thickener Clay Lithium Complex Lithium Complex

Grade NGLI 1.5 2.0 2.0

Moly-Fortified No Yes Yes

Dropping Pt. 310 C (590 F) 288 C (550 F) 288 C (550 F)

Field Personnel Note: The product listed above is the approved source that meets or exceeds HYSTER

specifications. The use of products other than that listed above is unauthorized.

Required for W50Z - Cold Storage/Arctic Packages

Application Cold Storage/Arctic Package

Oil Synthetic

Thickener Lithium Complex

Dropping Point Approximately +288 C(+550F)

Base Oil Viscosity (SUS) 151 @ +40 C(+104F)

Nominal Operating Temperature Range 40 to +122 C( 40 to +250 F)

Identification Container must be plainly marked with

supplier’s product identification.

Approved Sources

AMSOIL GHD Synthetic NGLI #2 GC-LB

Field Personnel Note: The product listed above is the ONLY approved source that meets or exceeds

HYSTER specifications. The use of products other than that listed above is unauthorized.

Weight 8000 SRM 1010

Hydraulic System

Operating Pressure1Ampere Draw2Relief Setting

Truck Size Volts No Load Rated Load No Load Rated Load Pressure3Amp Draw

4000lb 24 2.1 MPa

(300 psi) 7.7 MPa

(1800 psi)

25 70 17.15 MPa

(2450 psi)

4500lb 12 3.85 MPa

(550 psi) 12.6 MPa

(1800 psi)

60 100 19.6 MPa

(2800 psi)

150

4500lb 24 3.08 MPa

(440 psi) 11.9 MPa

(1700 psi)

30 75 18.9 MPa

(2700 psi)

110

5000lb 24 2.62 MPa

(380 psi) 14.8 MPa

(2152 psi)

24 98 20.0 MPa

(2900 psi)

120

Standard Specifications

Hydraulic Tank Capacity - 0.75 liter (25.4 oz)

Pump Displacement (24 Volts) - 1.25 cm3/rev (0.076 in.3/rev)

Pump Displacement (12 Volts) - 1.25 cm3/rev (0.076 in.3/rev)

Creep Rate - 6.4 mm (0.25 in.) Maximum In 10 Minutes @ 21 C(70F) Oil Temperature

Footnotes

1±0.35 MPa (±51 psi) @ 21 C(70F) Oil Temperature

2±10 Amps @ 1.270 Battery Specific Gravity

3+0.6 to 0.0 MPa (+87 to 0 psi) @ 21 C(70F) Oil Temperature Full Flow

Weight

BASIC TRUCK WITHOUT BATTERY

Weight Battery

Compartment

Inside Di-

mension

Fork

Length

900 mm

(35.4 in.)

Weight

Fork

Length

1050 mm

(41.3 in.)

Weight

Fork

Length

1200 mm

(47.2 in.)

Weight

Fork

Length

1400 mm

(55.1 in.)

Weight

Fork

Length

1500 mm

(59.0 in.)

Weight

4000 lb 193 × 700 mm

(7.6 × 27.5 in.) 243 kg

(536 lb) 258 kg

(568 lb) 272 kg

(600 lb) N/A 301 kg

(665 lb)

4500 lb

12V

193 × 780 mm

(7.6 × 30.7 in.) 238 kg

(525 lb) 253 kg

(557 lb) 267 kg

(589 lb) N/A 297 kg

(654 lb)

4500 lb

24V

218 × 700 mm

(8.6 × 27.5 in.) 249 kg

(548 lb) 263 kg

(580 lb) 278 kg

(612 lb) N/A 307 kg

(677 lb)

5000 lb 218 × 700 mm

(8.6 × 27.5 in.) 237 kg

(522 lb) 245 kg

(540 lb) 251 kg

(553 lb) 260 kg

(573 lb) 266 kg

(586 lb)

8000 SRM 1010 Battery Specifications and Adjustments

Tires

Weight and Voltage Drive Tire Load Wheel

4000 lb 9×4in. 3.25 × 4.5 in.

4500 lb, 12 Volts 9×4in. 3.25 × 4.5 in.

4500 lb, 24 Volts 9×4in. 3.25 × 4.5 in.

5000 lb 9×4in. 3.25 × 4.5 in.

Torque Specifications

CASTER ASSEMBLY

Mounting Capscrews (3 each)

57 N•m (42 lbf ft)

MASTER DRIVE UNIT

Motor Mount Studs (3 each)

20 N•m (15 lbf ft)

Transmission to Frame Mounting Bolts (4 each)

Torque to 54 N•m (40 lbf ft)

Then loosen, and torque to 34 N•m (25 lbf ft)

Drain Plug

41 N•m (30 lbf ft)

Fill-Level Plug

41 N•m (20 lbf ft)

27 N•m (20 lbf ft)

STEERING

Steer Handle to Tiller Bracket Screws (2 each)

115N•m(85lbfft)

Butterfly Throttle Control to Handle

Screws (2 each)

1N•m(8.9lbfin)

Gas Springs Mounting Stud (1 each)

25 N•m (18.5 lbf ft)

Control Arm Support Bracket Pivot

Pins (2 each)

142 ±7 N•m (105 ±5 lbf ft)

BRAKE

Mounting Capscrews (3 each)

11 N•m (25 lbf in)

Traction Motor Power Wire Nuts (4 each)

5N•m(44lbfin)

Controller Hardware Connections

M5 metric screw 3 N•m (26.5 lbf in)

M5 metric nut 4.5 N•m (40 lbf in)

M5 metric screw and nut 88 N•m (115 lbf in)

LIFT MECHANISM

Hydraulic Power Unit Mounting

Capscrews (3 each)

24 N•m (18 lbf ft)

Battery Specifications and Adjustments

4000 LB - 24 VOLT

Battery Compartment is shown in Figure 1.

Battery Specifications and Adjustments 8000 SRM 1010

Figure 1. Battery Compartment

Number of

Cells Cell Size Ampere

Hours

(Max)

Kilowatt

Hours

(Max)

Com-

partment

Length (X)

Com-

partment

Width (Y)

(Max)

Recom-

mended

Height

(Max)

Weight

(Max)

Standard Battery Pack

with 25 amp charger 158 3.8 721.4 mm

(28.4 in.) 200.7 mm

(7.9 in.) 607 mm

(23.9 in.) 141 kg

(310 lb)

GNB PalletPro™ Battery

Pack with 25 amp charger 195 4.4 693.4 mm

(27.3 in.) 190.5 mm

(7.5 in.) 670.6 mm

(26.4 in.) 170 kg

(375 lb)

Industrial

Battery,

with 12 cells 85 170 4.0 635 mm

(25 in.) 167.6 mm

(6.6 in.) 591.8 mm

(23.3 in.) 183 kg

(403 lb)

4500 - 12 VOLT

Number of

Cells Cell Size Ampere

Hours

(Max)

Kilowatt

Hours

(Max)

Com-

partment

Length (X)

Com-

partment

Width (Y)

(Max)

Recom-

mended

Height

(Max)

Weight

(Max)

685 425 5.0 662.3 mm

(26.1 in.) 195.6 mm

(7.7 in.)

591.8 mm

(23.3 in.) 198 kg

(436 lb)

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