Keeping a Hyster W40XT pallet truck in service is the single job behind these 414 pages, which share coverage with the wider XT series of trucks. Wiring, cabling and schematic diagrams in this Hyster W40XT service manual PDF trace each electrical circuit with its sequence of operation and fault procedures, while hydraulic schematics lay out the lifting mechanism. Curtis transistor motor controller troubleshooting walks through thermal protection and the power circuit, and the fastener section gives metric and inch torque tables with conversion charts. Set shoe to drum clearance at 0.127 mm (0.005 in.). Then hold the brake release cam to upper adjusting nut gap between 0.38 and 0.76 mm (0.015 to 0.030 in.). Maybe your job is brake linkage removal and cable installation; that sequence is written out for each model group. Bookmarked and text-searchable, the pages also print cleanly, so you can keep a working paper copy of whichever section you need.
What's Inside This Hyster W40XT Manual
| System | Pages | Key Topics |
|---|---|---|
| Brakes | 1-24 | Repairs - General, Brake Shoe Assembly, Brake Shoe Removal, Brake Shoe Installation, Brake Linkage Removal, Brake Linkage and Cable Installation, Brake Adjustment, Brake Linkage Adjustment, Brake Operation, Service Brake, Parking Brake, Checking Brake Clearance, Adjusting Brake Clearance, Troubleshooting Chart, Repair Procedures, Checks, Adjustments, Snap Rings, Steering Control Handle |
| Curtis Transistor Motor Controller | 25-74 | General, Principles of Operation, Transistor Controller, Thermal Protection, Power Circuit, Troubleshooting |
| Electrical System | 75-104 | Circuit Schematics, Sequence of Operation, Fault Procedures, Electrical Components |
| Industrial Battery | 105-132 | Battery Maintenance, Charging, Safety Precautions, Battery Specifications, Troubleshooting |
| Metric and Inch (SAE) Fasteners | 133-152 | Fastener Identification, Torque Tables, Cotter Pins, Conversion Tables |
| Diagrams | 153-214 | Wiring Diagrams, Cabling Diagrams, Schematic Diagrams, Electrical Components |
| Capacities, Specifications, and Maintenance | 215-224 | Hydraulic System, Weight, Torque Specifications, Lifting Mechanism, Troubleshooting, Tires |
| Brakes (W40XT and W45XT) | 225-236 | Top Steer Handle |
| Capacities and Specifications (W40XT and W45XT) | 237-240 | |
| Diagrams with ELM | 241-276 | Wiring Schematic, Options Schematic, Optional Wiring |
| Frame | 277-307 | |
| Lifting Mechanism (W40XT and W45XT) | 308-319 | |
| Lifting Mechanism (B/C60-80XT) | 320-339 | Tandem Wheels |
| Master Drive Unit (MDU) | 340-349 | |
| Periodic Maintenance | 350-373 | Maintenance Schedule, Wheels and Bearings, Motor Brushes |
| Steering Mechanism (W40XT and W45XT) | 374-385 | Flow Regulator Valve, Steering Relief Valve |
| Steering Mechanism (W60-80XT) | 386-400 | |
| Walkie Hydraulic Systems | 401-414 | Control Valve |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Brake release cam to upper adjusting nut clearance | 0.38 to 0.76 mm (0.015 to 0.030 in.) | p. 17 |
| Brake shoe to brake drum clearance | 0.127 mm (0.005 in.) | p. 18 |
| Control wire size | 1.5 mm2 (AWG 16 gauge) | p. 101 |
| Alternative control wire size | 1 mm2 (18 gauge) | p. 101 |
| 24 V battery cell potential difference | 2 volts | p. 113 |
| Bicarbonate of soda solution concentration | 0.5 kg of soda for every 4 liters of water | p. 116 |
| Specific gravity of a fully charged battery | 1.265 to 1.310 at 25°C (77°F) | p. 369 |
| Drive Wheel Capscrews Torque | 190 to 217 N•m (140 to 160 lbf ft) | p. 221 |
| Motor and Solenoid Terminal Nuts Torque | 9 N•m (7 lbf ft) | p. 221 |
| Motor Mount Screws, Capscrew (2) | 19 N·m (14 lbf. ft.) | p. 8 |
| Motor Mount Screws, Hex Socket (1) | 19 N·m (14 lbf. ft.) | p. 8 |
| Hydraulic Tank Capacity | 0.95 Litres (1.0 qt.) | p. 238 |
Hyster W40XT Common Problems This Manual Covers
Hyster W40XT brake will not release and drags with the parking brake off
Verify the drive tire is off the ground on blocks under each side of the frame, and disconnect the battery connector and tag it DO NOT CONNECT, both per page 6. Adjust the brake following page 18, setting brake shoe to drum clearance at 0.127 mm (0.005 in.) with a feeler gauge. Replace worn brake linkage. Adjust or replace a brake switch that is not working properly.
Manual Section: Brake Troubleshooting p. 22Brake shoes make noise and the brake will not stop the unit correctly
Inspect the brake shoes with the frame on blocks and the battery connector separated and tagged, as page 6 requires. Replace worn shoes. Clean or replace shoes with oil or grease on them. Adjust the linkage and shoes per page 18 to 0.127 mm shoe to drum clearance. Replace a broken brake spring, and adjust or replace a faulty brake switch. Lower the truck and test operation before returning it to service.
Manual Section: Brake Troubleshooting p. 22Truck will not move in either direction after key switch ON and direction control rotated
Verify the starting sequence on page 37: key switch ON, close the brake switch, then rotate the Direction/Speed control. Rotating the control before the first two steps locks out travel through the Static-Return-To-Off function, so return it to neutral and repeat. Check that the key switch supplies battery voltage to the brake switch, with the drive wheel raised to prevent truck movement, as page 50 warns.
Manual Section: Curtis Transistor Motor Controller p. 37Truck drives in one direction only, direction switch contacts do not close in the other
Verify the drive wheel is raised off the floor before any check made with the battery connected, as page 50 warns. Check for battery voltage at the wire 8 terminal of the traction reverse or direction switch with both switches in neutral, following page 62. Clean and repair connections in that circuit first; page 67 notes the low-level control circuits are disturbed by contamination, wear or damage.
Manual Section: Electrical System p. 62Curtis controller sets fault codes intermittently over potholes or with a low battery
Check battery charge first: fully charged reads 1.265 to 1.310 specific gravity at 25°C (77°F), per page 369. Disconnect the battery and separate the connector before opening the hood (page 61), and discharge the controller capacitor, never with a screwdriver (page 6). Clean and repair every connection in the affected circuit. Page 67 notes Curtis 1243 codes can come from potholes or very low battery, not a failed controller.
Manual Section: Electrical System p. 67Contactor contacts welded after operating on a low battery, circuit will not reset
Inspect the contactors for welded contacts before connecting a charged battery, as page 370 warns; with welded contacts the circuit will not reset and truck operation cannot be controlled. Disconnect the battery and separate the connector before working on the contactors (page 56). When servicing the contacts, do not lubricate them, do not use a file on them, and do not lose the plunger springs (page 58).
Manual Section: Capacities, Specifications, and Maintenance p. 370Frequently Asked Questions
How do I troubleshoot a Hyster W40XT that will not move?
If the directional contactors close normally but the lift truck will not move, check the traction fuse for damage. If the fuse is intact, check for battery voltage between the B+ and B- terminals of the controller. If voltage is present, check for battery voltage at the P2 terminal of the direction contactors. Refer to page 64 for the complete troubleshooting flow chart. p. 64
What are the torque specifications for the drive wheel capscrews on the Hyster W40XT and W60XT pallet trucks?
The drive wheel capscrews (5 each) on a W60XT should be tightened to a torque of 190 to 217 N•m (140 to 160 lbf ft). p. 219
What is the correct hydraulic oil capacity for a Hyster W40XT pallet truck?
The hydraulic tank capacity for the W60XT is 1.4 liters (1.5 qt). p. 219
How do I adjust the fork height on a B60-80XT?
Adjust the rear fork height adjustment screws on each side, with the battery in place, to obtain a fork height of 85.9 to 88.9 mm (3.38 to 3.5 in) at the rear of the forks. For the front, adjust the nuts to obtain a fork height of 82.5 to 84.1 mm (3.25 to 3.31 in). p. 336
What is the torque specification for the pull rod jam nuts on a T5XT in the Hyster W40XT service manual?
The pull rod jam nuts (4 each rod) on a T5XT should be tightened to 176 N•m (130 lbf ft). p. 221
Is this Hyster W40XT manual a PDF I download?
A single searchable PDF file of 414 pages, downloadable right after payment. Nothing ships, nothing waits in the mail.
Is printing allowed for this Hyster W40XT Service Manual?
Yes. Print the pages or sections you need for your own shop use. Any standard printer works.
