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]
©2006 HYSTER COMPANY i

"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)
1

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.
2

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.
3

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)
85
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)
4

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.
5

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.)
d
591.8 mm
(23.3 in.) 198 kg
(436 lb)
6

8000 SRM 1010 Battery Specifications and Adjustments
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 5.0 792.5 mm
(31.2 in.) 198 mm (7.8 in.) 591.8 mm (23.3 in.) 232 kg
(512 lb)
685 510 6.0 777.3 mm
(30.6 in.)
a
195.6 mm
(7.7 in.)
c
591.8 mm
(23.3 in.) 231 kg
(510 lb)
Note:If Y is less than 184 mm (7.25 in.), A supplemental spacer is required.
a–Use6.35mm(1.26in.) spacer.
b– Use 25.4 mm (1 in.) spacer.
c–Use16mm(0.63in.) spacer.
d–Use32mm(1.26in.) spacer.
e–Use16mm(0.63in.) spacer.
4500 AND 5000 LB - 24 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)
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.) 163 kg
(360 lb)
12 75 150 3.5 642.6 mm (25.3 in.)
b
162.6 mm
(6.4 in.)
e
591.8 mm
(23.3 in.) 186 kg
(410 lb)
12 85 170 3.9 642.6 mm (25.3 in.)
b
162.6 mm
(6.4 in.)
e
591.8 mm
(23.3 in.) 193 kg
(425 lb)
12 100 200 4.6 642.6 mm (25.3 in.)
b
162.6 mm
(6.4 in.)
e
668 mm
(26.3 in.) 213 kg
(470 lb)
12 75 225 5.2 652.8 mm (25.7 in.)
b
223.5 mm
(8.8 in.) 591.8 mm (23.3 in.) 245 kg
(540 lb)
12 85 255 6.0 652.8 mm
(25.7 in.)
b
223.5 mm
(8.8 in.) 591.8 mm (23.3 in.) 245 kg
(540 lb)
Note:If Y is less than 210 mm (8.25 in.), a supplemental spacer is required.
a–Us
e 6.35 mm (1.26 in.) spacer.
b–Us
e25.4mm(1in.) spacer.
c–Use16 mm (0.63 in.) spacer.
d–Use32 mm (1.26 in.) spacer.
e–Use16 mm (0.63 in.) spacer.
7

NOTES
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8

TECHNICAL PUBLICATIONS
8000 SRM 1010 10/06 (9/05)(1/02) Printed in U.S.A.