Hyster W40Z Periodic Maintenance Procedure
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Hyster W40Z Periodic Maintenance Procedure

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PERIODIC
MAINTENANCE
W40Z [B218]; W45Z [C215];
W50Z [D215]
PART NO. 1499808
8000 SRM 1009

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February 28, 2025

what percent of lead/acid is the battery comprised of?

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Summary of Contents for Hyster W40Z

  • Page 1 PERIODIC MAINTENANCE W40Z [B218]; W45Z [C215]; W50Z [D215] PART NO. 1499808 8000 SRM 1009...
  • Page 2 • 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.

  • Page 3: Table Of Contents

    Battery Maintenance ............................How to Charge the Battery ........................... Equalizing Charge............................. Normal Charge ............................Maintenance-Free Battery Charger ......................Battery Charger (W40Z Only) ........................How to Change the Battery........................... Maintenance Schedule............................Checks and Inspection Procedures ....................... Hydraulic System ............................Lifting Mechanism ............................
  • Page 4 "THE QUALITY KEEPERS" HYSTER APPROVED PARTS...

  • Page 5: General

    Maintenance Schedule. Never tow the lift truck faster than the speed Service Manuals are available from your Hyster lift of a person walking. Steering can be difficult truck dealer to help users who do their own repairs.

  • Page 6: How To Put A Lift Truck On Blocks

    General 8000 SRM 1009 truck. DO NOT walk or stand between the towing load must be equal to or greater than the weight vehicle and the lift truck. of the disabled lift truck. Install a load of approx- imately half the maximum capacity on the forks 1.

  • Page 7: How To Raise Drive/Steer Tire

    8000 SRM 1009 General How to Raise Drive/Steer Tire WELDING REPAIRS 1. Put blocks on each side (front and back) of the WARNING load wheels to prevent movement of the lift truck. Forklift truck frames and components may have polyurethane paint. Welding, burning, or 2.

  • Page 8: Battery Maintenance

    Battery Maintenance 8000 SRM 1009 Battery Maintenance HOW TO CHARGE THE BATTERY Table 1. Specific Gravity Corrections Specific Cor- Cor- WARNING Electrolyte Gravity rection rect DO NOT put tools on the battery. Temperature Reading Points Value If the lift truck was operated with a low battery, 1.210 +0.003 1.213...

  • Page 9: Maintenance-Free Battery Charger

    Manual. compartment. Make sure the battery cables have clearance to move during lifting and Battery Charger (W40Z Only) lowering of the forks. Make sure that the re- placement battery is the correct voltage and For lift trucks equipped with the standard battery weight as shown on the capacity plate.

  • Page 10: Maintenance Schedule

    NOT OPERATE tag on the control handle. Re- Service manuals are available from your Hyster move the key from the key switch. dealer to help users who do their own maintenance.

  • Page 11: Hydraulic System

    8000 SRM 1009 Maintenance Schedule Hydraulic System hydraulic pump assembly. The fluid level full mark is labeled on the hydraulic reservoir. The hydraulic reservoir fluid level can be seen through the reser- WARNING voir. If levels do not meet necessary requirements, Always wear the proper protective equipment add hydraulic oil.

  • Page 12: Lifting Mechanism

    Maintenance Schedule 8000 SRM 1009 1. Raise the forks slowly without a load. Check for smooth operation and mechanical interference. Mechanical interference is caused by damaged or worn linkage or shafts, or by incorrect adjust- ment of the tension rods. 2.

  • Page 13: Electrical And Battery

    8000 SRM 1009 Maintenance Schedule 5. Check the operation of the traction reverse func- area. Make the acid neutral with a solution of tion. Slowly rotate the speed/direction control for sodium bicarbonate (soda) and water. Acid in slow travel in the control handle direction. Push the eyes must be immediately flushed with wa- the traction reverse button without changing the ter continuously for 15 minutes, then seek med-...

  • Page 14: Wheels And Tires

    Maintenance Schedule 8000 SRM 1009 Wheels and Tires carry more of the load. If the casters are not shimmed properly, the caster can reduce the load on the drive tire and reduce the ability of CAUTION the drive tire to stop the truck. Whenever wheels have been installed, check all wheel nuts after 2 to 5 hours of operation.

  • Page 15: Recommended Schedule Of Maintenance

    (Prior to each shift) Only the 8-hour checks are to be performed by the operator. Have a qualified technician correct all problems in accordance with appropriate Hyster maintenance instructions. A - Every 8 Hours X - Indicates Visual Inspection, Repair, or...
  • Page 16 (Prior to each shift) Only the 8-hour checks are to be performed by the operator. Have a qualified technician correct all problems in accordance with appropriate Hyster maintenance instructions. A - Every 8 Hours X - Indicates Visual Inspection, Repair, or...
  • Page 17 8000 SRM 1009 Recommended Schedule of Maintenance LUBRICATION CHECK Blow off, clean when necessary, and inspect for damage. A - Every 8 Hours X - Indicates Visual Inspection, Repair, or B - Every 350 Hours Replace as Required C - Every 2000 Hours O - Indicates Drain and Fill Component: Lubricate - Chassis (All Fittings)
  • Page 18 Recommended Schedule of Maintenance 8000 SRM 1009 HYDRAULIC SYSTEM CHECK A - Every 8 Hours X - Indicates Visual Inspection, Repair, or B - Every 350 Hours Replace as Required C - Every 2000 Hours O - Indicates Drain and Fill Component: All Hydraulic Hoses and Fittings for Leaks, Wear, Kinks, Flattening, and Charring For General Leaks...
  • Page 19 8000 SRM 1009 Recommended Schedule of Maintenance ELECTRICAL SYSTEM CHECKS NOTE: DO NOT use Steam to Clean Electrical Parts A - Every 8 Hours X - Indicates Visual Inspection, Repair, or B - Every 350 Hours Replace as Required C - Every 2000 Hours O - Indicates Drain and Fill Component: Clean all Controls...

  • Page 20: Lubrication Instructions

    Lubrication Instructions 8000 SRM 1009 ROAD AND LOAD TEST TRUCK The following items must be tested at initial installation of the truck and after every maintenance inspection or repair. Test the rated load in a clear area. Report any questionable functions or unusual noises. A - Every 8 Hours X - Indicates Visual Inspection, Repair, or B - Every 350 Hours...

  • Page 21: Every 2000 Hours Or 2 Years

    8000 SRM 1009 Lubrication Instructions Hydraulic Reservoir Breather - Remove drive Never operate the pump without the proper unit cover. Remove breather and clean with a suit- amount of oil in the hydraulic system. able cleaning solution, blow dry with compressed air, operation of the hydraulic pump with low oil and install.
  • Page 22 Lubrication Instructions 8000 SRM 1009 Figure 8. Lubrication Locations...
  • Page 23 8000 SRM 1009 Lubrication Instructions Legend for Figure 8 Item Location No. of Fittings Compression Rod 2 per rod Load Link 2 per load link Gear Oil Load Wheel 1 per load wheel Hydraulic Oil Lower Link 4 per lower link Steer Bearings Upper Link...
  • Page 24 NOTES ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________...
  • Page 26 TECHNICAL PUBLICATIONS 8000 SRM 1009 2/07 (9/05)(12/03)(1/02) Printed in U.S.A.

This manual is also suitable for:

W45zW50zB218C215D215

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