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SERVICE REPAIR W45Z [C215]


100 SRM 1015

General

General DESCRIPTION The main frame has mounts for the lifting mechanism, the electrical system parts, the hydraulic pump assembly, and the master drive unit (MDU). Repair procedures for major systems/parts that fasten 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

1. 2. 3. 4. 5.

FORKS FRAME UPPER COVER MOTOR COVER RH MOTOR COVER LH

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.

6. 7. 8. 9.

COUNTERSUNK CAPSCREW LOWER COVER WASHER BUTTON HEAD CAPSCREW

Figure 1. Frame Weldment and Covers W40Z, W45Z, and W50Z

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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 decomposition of the paint may release isocyanates. These chemicals are allergic sensitizers to the skin and respiratory tract and overexposure Always may occur without odor warning. utilize good industrial hygiene practices including 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 unless you have proper authorization and training. Repairs and adjustments that are not correct can cause a dangerous operating condition. Do not operate a lift truck that needs repairs. Report the need for repairs to your supervisor 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 individual 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. Disconnect 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.

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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 securing 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 secure the rocker arms to the drive unit frame. See Rocker Arm, Install in Lifting Mechanism 4000 SRM 1008.


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 cylinder to the fork frame. See Hydraulic Cylinder, Install 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 clothing 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 compartment. The battery compartment must be kept clean to ensure 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.

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 without 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 electrolyte. 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.

Contact of objects between the battery posts can result in personal injury and severe damage to the lift

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Label Replacement

100 SRM 1015

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

1. CRANE 2. SPREADER BAR

3. INSULATED STRAPS 4. BATTERY

Figure 2. Changing the Battery

Make sure the voltage and weight of the replacement battery is correct as shown on the nameplate. Make sure the battery is the correct size and weight for the lift truck.

For the following instructions, refer to Figure 2.

1. Remove any obstructions in battery compartment (i.e., battery cables or tools).

Remove

2. Lower new battery into battery compartment.

1. Move lift truck under overhead crane or other suitable lifting device.

3. Connect battery cable connector. Adjust location of battery to allow proper connection of cables.

2. Block drive tire to prevent movement of lift truck.

4. Adjust the brackets on each side of the battery and tighten the capscrews, lockwashers, and nuts to retain the battery.

3. Turn key switch OFF, disconnect battery connector, 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. Remove spreader bar and insulated straps from battery.

Battery Spacer Adjustment 5. Connect spreader bar to battery using insulated straps and lift battery out of lift truck.

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 damaged, they must be replaced. See Figure 3.

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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 complete before installing a new nameplate cover. Fasten the nameplate cover with the rivet heads outside.


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.

1. 2. 3. 4. 5. 6.

LABEL (HYSTER) COVER LABEL (WARNING) RIVET LABEL (PINCH WARNING) LABEL (US PATENTS AND TRADEMARKS)

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 removed from under the label and the corners and edges are tight.

7. 8. 9. 10. 11.

LABEL (DASH) NAMEPLATE LABEL OPERATORS MANUAL LABEL (HYSTER) LABEL (BATTERY DISCHARGE NOTICE)

Figure 3. Label and Decal Location

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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 solvents, always follow the recommendations of the manufacturer.

2. Remove the top surface of paint and all rust from the metal using sandpaper. Paint all metal surfaces where the paint is completely removed using 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.

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.

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 injury 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.

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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.


100 SRM 1015

1. 2. 3. 4.

LOAD WHEEL FITTING ROLLER BEARING

Load Wheels

5. 6. 7. 8.

BUSHING AXLE FITTING PIN

Figure 4. Load Wheel and Link Assembly

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4000 SRM 1008

General

General LIFT LINKAGE This section has the description and repair procedures for the W40/45/50Z units. The lifting mechanism is operated by the hydraulic system. Hydraulic fluid extends the lift cylinder, operates the lift linkage, and raises the forks. On all motorized lift trucks, when the lift button on the control handle is depressed, the hydraulic pump

1. LOWER LINK (RH) 2. LOWER LINK (LH)

sends high pressure hydraulic fluid to the lift cylinder. 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.

3. FORK 4. LOAD WHEEL Figure 1. Lift Linkage

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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 injury 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. Connect 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.

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 bearings. 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.

3. Put blocks under both forks and under the drive end of truck. See the section How to Put a Lift Truck on Blocks.

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.

4. Press the lower button just enough to relieve pressure from the load wheels.

3. Install the roll pin through the link to secure the axle shaft.

5. Move the key to the OFF position. Disconnect the battery.

4. Reconnect the battery. Move the key to the ON position.

6. Drive out the roll pin retaining the load wheel axle shaft to the link. Repeat for other side.

5. Press the lift button to fully extend the lift link.

7. Remove the axle shaft and bushings from the link. Remove bearings and load wheel assembly 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 bearings. Do not attempt to clean or lubricate sealed

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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.


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4000 SRM 1008

1. 2. 3. 4.

Rear Link and Load Wheel

LINK GREASE FITTING ROLLER BEARING

5. 6. 7. 8.

BUSHING AXLE SHAFT FITTING 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 injury 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. Connect 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.

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Compression Rod

4000 SRM 1008

6. Disconnect the load wheel link from the compression rod yoke:

2. Install the load wheel and link assembly to the fork:

a. Remove the roll pin securing the pivot pin in the yoke.

a. Align the pallet exit roller and load wheel link with mounting holes in fork.

b. Remove the pivot pin.

b. Install the connecting pivot pin and align holes with a punch.

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.

c. Secure with the roll pin. 3. Connect the load wheel link with the compression rod: a. Check condition of yoke components including 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 injury 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 battery 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

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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. 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.


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 compression 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 battery 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 insulated straps.

WARNING

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.

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 injury or property damage.

2. Align the lower link with the fork frame and install the lower link pivot pin. Install the roll pin to retain the pivot pin.

1. Use the lift button to raise the lift truck to its maximum height.

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.

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. 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.

4. Remove covers.

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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.

1. FITTING 2. PIN 3. FITTING

8. Turn the key to the ON position and use the lower button to lower the lift truck to its minimum height. 9. Test the operation of the motorized hand truck before returning the truck to service.

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 injury 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.

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3. Remove the drive unit compartment cover to access 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.

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Hyster C215 (W45Z) Forklift Service Repair Manual  

Hyster C215 (W45Z) Forklift Service Repair Manual  

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